a b s t r a c tA 3D contact analysis and modeling suite of tools are developed and introduced in this work. The "3D Contact Map" of an electrical contact interface is presented demonstrating the 3D nature of the contact. It gives information on where the electrical contact spots in a 3D surface profile are located. An X-ray Computer Tomography (CT) technique is used to collect the 3D data to a resolution of around 5 μm of a real un-dismantled contact interface for analysis. Previous work by Lalechos and Swingler presented "2DContact Map" on a 2D contact profile from collected 3D data to a resolution of around 8 μm. The main advantages of both 3D and 2D mapping techniques focus on the fact that they are non-destructive and there is no need to dismantle the component of interest. This current work focuses on the 3D mapping technique showing its advantages over the 2D mapping technique. For test purposes, a 16 A rated AC single pole switch is scanned after two different current loading tests (0 A and 16 A). A comparison for the total mechanical area of contact, the number of contact spots and the total contact resistance is conducted using both the 2D and 3D mapping techniques to a resolution of around 5 μm.
The electrical contact is an important phenomenon that should be given into consideration to achieve better performance and long term reliability for the design of devices. Based upon this importance, the electrical contact interface has been visualized as a ‘‘3D Contact Map’’ and used in order to investigate the contact asperities. The contact asperities describe the structures above and below the contact spots (the contact spots define the 3D contact map) to the two conductors which make the contact system. The contact asperities require the discretization of the 3D microstructures of the contact system into voxels. A contact analysis approach has been developed and introduced in this paper which shows the way to the 3D visualization of the contact asperities of a given contact system. For the discretization of 3D microstructure of contact system into voxels, X-ray Computed Tomography (CT) method is used in order to collect the data of a 250 V, 16 A rated AC single pole rocker switch which is used as a contact system for investigation.
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