Fretting corrosion driven by thermal cycling or vibration is a leading failure mode in base-metal connector systems. The study tested single-row PC and automotive connectors under multi-frequency and single-frequency vibration, using modified housings and laser displacement measurement to observe relative motion at the contact interface directly.
Fretting showed a clear threshold: below it, almost no degradation was detectable; above it, degradation rate scaled roughly linearly with excitation acceleration. Because acceleration is proportional to displacement amplitude at a single frequency, the model was rewritten in terms of interface displacement and matched measurements better.
Across 3, 8 and 12 inch cable bundle lengths, the threshold displacement fell as cable length increased. Housing motion tracked terminal motion at low frequencies but needed a transfer-function correction near resonance peaks. Samples treated with a polyolefin contact lubricant showed no significant fretting at 10–500Hz and up to 16Grms.
Compiled by the committee. Data and conclusions follow the original sources; please credit when republishing.
Source：International Cable & Connector (Big-Bit) · Advanced Basic Materials Committee
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