Course I - Lecture 10 - Contact Materials
Course I - Lecture 10 - Contact Materials
Electric A in
i Gases
G – Contact
C t tM Materials
t i l
Training of ILJIN engineers in Sarajevo
Course I : Electric arc
Lecture No 10
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Prof.dr. Mirsad Kapetanovic
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High-conductivity metals
All electric contacts for power applications contain a high percentage of those metals.
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Prof.dr. Mirsad Kapetanovic
Symbol: Cu
A ductile,
ductile malleable
malleable, metallic element that is an
excellent conductor of heat and electricity.
It is widely used for electrical wiring, water piping,
and corrosion-resistant parts, either pure or in
alloys such as brass and bronze.
Atomic number 29; atomic weight 63.55; melting
point 1083°C; boiling point 2595°C; specific gravity
8.92; the valences (see next slide) of copper are 1
and 2.
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Prof.dr. Mirsad Kapetanovic
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What are valences and radicals (in chemistry)
In chemistry,
chemistry a radical (more precisely,
precisely a free radical) is an atom,
atom molecule,
molecule or ion that
has unpaired valence electrons or an open electron shell, and therefore may be seen as
having one or more unused covalent bonds.
With some exceptions, these unused bonds make free radicals highly chemically
reactive towards other substances, or even towards themselves. Therefore, most
radicals are reasonably stable only at very low concentrations in inert media or in
vacuum.
A notable example of free radical is the hydroxyl radical (HO), a molecule that is one
hydrogen atom short of a water molecule and thus has one unused bond.
On the other hand, the hydroxyl anion (HO−), the oxide anion (O2−) and the carbenium
cation (CH+3) are not radicals, since the bonds that may appear to be unused are in fact
resolved by the addition or removal of electrons.
Indeed, radicals are intermediate stages in many chemical reactions.
In living organisms, the free radicals and their reaction products regulate many
processes, such as blood pressure, for example.
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Prof.dr. Mirsad Kapetanovic
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High-conductivity metals - copper (Cu)
Copper is most commonly used as contact material due to its high conductivity.
Copper contacts can be made from extruded bar stock, forged, machined and can be
stamped from plates.
The metal is quite ductile, but can be hardened by additions of zinc (Zn) to form
brass,, or tin (Sn),
( ), aluminum (Al),
( ), silicon (Si),
( ), nickel (Ni),
( ), silver (Ag)
( g) and other
elements to form various bronzes.
Copper contacts can be bolted, welded or brazed.
When no oxide is present the material has a low contact resistance. In bolted or stab
contacts, the contact resistance remains low for long periods of time.
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Prof.dr. Mirsad Kapetanovic
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Prof.dr. Mirsad Kapetanovic
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High-conductivity metals - silver (Ag)
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Prof.dr. Mirsad Kapetanovic
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High-conductivity metals - silver (Ag)
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Prof.dr. Mirsad Kapetanovic
It produces very thin oxide and sulfide films. Silver oxides are very unstable, so at the
temperature of 200°C, silver oxides will again reduce to pure silver.
Therefore, silver contacts give a very low contact resistance.
With the addition of copper, silver becomes harder and more force has to be used to
maintain
i t i llow values
l off contact
t t resistance.
i t
Silver oxide is very volatile and decomposes under arcing. Oxide and sulfide films are
easily ruptured by reasonable contact forces or wiping action.
Fretting is not a problem in power circuits.
The low boiling point does result in severe erosion by arcs, even at currents of only
tens of amperes. Erosion by arcs is enhanced by the release of oxygen which is usually
present in the metal.
Fortunately, arcs move very well on silver.
Silver is more inclined to welding of contacts than copper.
Silver contacts have found use in miniature low voltage circuit breakers where rapid
contact parting and rapid arc motion off the contacts prevents severe arc erosion and
contact welding.
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Prof.dr. Mirsad Kapetanovic
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High-conductivity metals - aluminum (Al)
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Cryolite
Corrosion resistance is excellent due to a thin surface layer of aluminum oxide that
forms when the metal is exposed to air, effectively preventing further oxidation.
Because of the oxidation, great care must be taken when electrical contact has to be
made to aluminum. The oxide is thin but tough. Once the oxide film has been broken on
this soft material,
material low contact resistances can be achieved.
achieved Aluminum is often silver
plated to prevent oxide formation.
For unplated aluminum, fretting is a serious problem. Bolted joints can be made with
pure aluminum if the interfaces are protected by special greases and the bolts are
spring loaded.
Aluminum cannot be used where arcs may occur. Its low melting and boiling
temperatures permit severe erosion.
In oxidizing environments the metal can even burn. Strong welds can form in non-
oxidizing atmospheres.
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Prof.dr. Mirsad Kapetanovic
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Cooper (Cu) vs Aluminum (Al)
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Prof.dr. Mirsad Kapetanovic
Copper is normally used for electrical wiring in residential and commercial buildings.
However, between 1965 and 1973 the price of copper increased significantly, and,
consequently aluminum wiring was installed in many buildings constructed during this
period.
An inordinately
y high
g number of fires occurred in these buildings,
g , and investigations
g
revealed that the use of aluminum posed an increased fire hazard risk over copper
wiring.
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Prof.dr. Mirsad Kapetanovic
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Bimetal technology
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Prof.dr. Mirsad Kapetanovic
High-conductivity alloys
What is an alloy?
• An alloy is homogeneous mixture of two or more elements, at least one of which is a
metal
metal.
• It usually has properties different from those of its component elements. Alloying can
improve mechanical and chemical properties of the metal.
• Electrical conductivity and the melting temperature of alloys are somewhat lower than
the mean value of components which corresponds to the mixing ratio.
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Prof.dr. Mirsad Kapetanovic
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High-conductivity Alloys
The most popular of these alloys is sterling silver, which consists of 92.5 % silver and 7.5 % copper.
The nickel content in silver-nickel can range from 10% to 40% by weight. This material is quite hard
and its thermal and electrical conductivity decreases as the nickel content increases.
Silver cadmium alloy, with 20% of cadmium, has excellent resistance to welding, due to the oxidation
of cadmium after arcing. Any free cadmium on the surface will form an oxide before silver.
There is a large number of alloys that consist of copper as the major constituent with other metals
added to increase its weld resistance and/or mechanical strength and/or lower the current at which
chopping occurs.
Silver bronze is a copper alloy containing up to 4% silver and 1.5% cadmium. It is significantly
harder than copper and more resistant to high temperature
temperature. Due to the greater strength of oxide
surface films, it has higher contact resistance than copper. It is used for contacts in switches and
circuit breakers.
The Cu-Bi (bismuth) binary alloy show a desirably low chopping current in vacuum interrupters.
The Cu-Cr (chromium) contact has found wide usage in vacuum interrupters for medium voltage
circuit breakers.
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Prof.dr. Mirsad Kapetanovic
Pertaining to this group are metals, which under normal conditions, are not covered
with surface layers. They are:
rhodium (Rh)
palladium (Pd)
ruthenium (Ru)
rhenium (Re)
osmium (Os)
iridium (Ir)
platinum (Pt)
silver (Ag), and
gold (Au)
All of these elements are precious or semi-precious metals and very expensive.
NOTE: A precious metal is a rare metallic chemical element of high economic value.
Chemically, the precious metals are less reactive than most elements, have high luster,
are softer or more ductile, and have higher melting points than other metals.
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Prof.dr. Mirsad Kapetanovic
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Chemically resistant metals and alloys
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Prof.dr. Mirsad Kapetanovic
Refractory metals
Refractory metals are a class of metals that are extraordinarily resistant to heat and
wear.
They are characterized by extremely high melting points (above 2100 K), which range
well above those of iron and nickel.
Th
These metals
t l are usually
ll hhard
d and
d very resistant
i t t tto welding
ldi and
d erosion
i caused
dbby th
the
electric arc.
These properties make them useful in high-power switching equipment.
Refractory metals are poorly resistant to oxidation and corrosion. Therefore this class of
material is not commonly used where fretting would be a problem. Because of their
surface oxide films they are not suitable for conductive contacts, although their
conductivity is relatively high.
Twelve metals constitute the group of refractory metals having melting points above
2100 K
K.
Primary representatives of refractory metals are:
tungsten (W, the melting point 3683 K) and
molybdenum (Mo, the melting point 2896 K)
Other refractory metals are: rhenium (Re), osmium (Os), tantalum (Ta), molybdenum
(Mo), iridium (Ir), niobium (No), ruthenium (Ru), hafnium (Hf), zirconium (Zr), vanadium
24 (V), and chromium (Cr).
Prof.dr. Mirsad Kapetanovic
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Sintered materials
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Prof.dr. Mirsad Kapetanovic
Sintered materials
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Sintered materials – silver-cadmium oxide contacts
Silver-cadmium oxide contacts can be made of an Ag-Cd alloy by heating the material
under high-pressure oxygen. This process results in the internal oxidation of the cadmium
to produce very fine CdO sites.
It is also possible to internally oxidize Ag-Cd powder and then manufacture the material
directly by pressing and sintering the powder.
Silver-cadmium oxide has found a wide usage in low voltage applications. Its contact
resistance does not increase as the contact structure is eroded.
It is very resistant to arc erosion for currents up to 3 kA. It has arc erosion significantly
lower than silver and silver-graphite contact material.
It is close to being the best contact material for low voltage load switches, low-current
circuit breakers and motor contactors.
The following sintered silver-metal oxide materials have been designed to replace
Ag/CdO: copper
A /S O2
Ag/SnO
Ag/NiO
Ag/ZnO
Ag/BiO
Ag/SnO/WO2, etc. silver-cadmium oxide
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Properties of contact materials
The following sequence lists different contact materials in the order of their resistance
to arc erosion, from worst to best:
1. Ag
2. Cu
3. Ag-Cu
5. Ag-Ni
All sintered contact materials have a stabilizing effect on the arc root, are unfavorable
for its mobility and have long immobility time.
In order to achieve optimum mobility of the arc on a contact surface, the, may be used.
asymmetrical contacts, contacts in which electrodes are made of different materials
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Prof.dr. Mirsad Kapetanovic
One of the main features of contact materials is their resistance to erosion due to
arcing.
Factors affecting the erosion of contact materials are the following:
a) physical properties of contact b) operating conditions
materials purpose of contacts (to carry
electrical conductivity current, making, breaking, arcing
thermal conductivity contacts, main contacts, ...)
thermal capacity type of load (current magnitude,
rated voltage, frequency of
softening temperature operation, ...)
melting point medium (air, oil, vacuum, SF6, ...)
boiling point type of application (circuit
mechanical strength breakers contactors,
breakers, contactors switches,
switches
hardness disconnectors, ...)
surface tension of melted contact
material
ratio of boiling points of
components for heterogeneous
materials
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Prof.dr. Mirsad Kapetanovic
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Properties of contact materials
Contact materials play a vital role in the switching performances of all switching
equipment.
They are called upon to meet very stringent requirements that are generally contrasting
in nature.
Some
S mechanical,
h i l metallurgical
t ll i l and
d electrical
l t i l requirements
i t they
th have
h to
t fulfill
f lfill are:
good mechanical strength
good thermal conductivity
low weld break forces
low erosion due to arcing
good electrical conductivity
low chopping currents
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Prof.dr. Mirsad Kapetanovic
There are a number of requirements set for contact materials. Table shows features of
some contact materials with regard to different requirements set out for the duration of
the work of contacts.
The choice of contact material, bearing in mind all the different requirements, comes
down to a compromise solution depending on the type and purpose of switching device.
In high voltage switches and circuit breakers, due to the high making and breaking
power, materials resistant to arc erosion are used for arc contacts.
Their unfavorable features related to normal load current conduction are usually
compensated for by main contacts which carry the current in closed position.
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Prof.dr. Mirsad Kapetanovic
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