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Evaluation of Contact Separation Force Testing as A Screening Methodology for Electrical Socket ContactsDuring system level testing intermittent and permanent open circuit failures of mated, crimp removable, electrical contact pairs were experienced. The root cause of the failures was determined to be low (but not zero) contact forces applied by the socket contact tines against the engaging pin. The low contact force reduces the effectiveness of the wiping action of the socket tines against the pin. The observed failure mode may be produced when insufficient wiping during mate, demate and small relative movement in use allows for the accumulation of debris or insulating films that electrically separate the contact pair. The investigation identified at least three manufacturing process control problems associated with the socket contacts that enabled shipment of contacts susceptible to developing low contact forces:

(1) Improper heat treatment of the socket tines resulting in plastic rather than elastic behavior;

(2) Overly thinned socket tines at their base resulting in reduced pin retention forces;

(3) Insufficient screening tests to identify parts susceptible to the aforementioned failure mechanisms.

The results from an extensive screening program of socket contacts utilizing the industry standard contact separation force test procedures are described herein. The investigation shows this method to be capable of identifying initially weak sockets. However, sockets whose contact retention forces may degrade during use may not be screened out by pin retention testing alone. Further investigations are required to correlate low contact retention forces with increased electrical contact resistance in the presence of insulating films that may accumulate in the use environment.
Document ID
20090005032
Acquisition Source
Goddard Space Flight Center
Document Type
Conference Paper
Authors
Christopher Green
(Goddard Space Flight Center Greenbelt, Maryland, United States)
Christopher Greenwe
(Perot Systems Corp. Greenbelt, MD, United States)
Jav Bnisse
(Perot Systems Corp. Greenbelt, MD, United States)
Henning W Leidecker
(Goddard Space Flight Center Greenbelt, Maryland, United States)
Krus, Dennis
(Perot Systems Corp. Greenbelt, MD, United States)
Date Acquired
August 24, 2013
Subject Category
Electronics And Electrical Engineering
Meeting Information
Meeting: Capacitor and Resistor Technology Symposium (CARTS)
Location: Jacksonville, FL
Country: US
Start Date: March 30, 2009
End Date: April 2, 2009
Sponsors: Institute of Electrical and Electronics Engineers
Funding Number(s)
CONTRACT_GRANT: NNG05-CA97C
Distribution Limits
Public
Copyright
Public Use Permitted.

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