This study investigates the arc-induced degradation mechanisms of Ag–Ni (90/10) electrical contacts under controlled laboratory cycling conditions using a custom PLC-controlled switching system. The degradation process is characterized by three distinct wear stages: initial arc erosion with localized material removal, a restructuring phase marked by melting and material redistribution, and a final film deposition stage leading to topographical homogenization but functional degradation. Raman spectroscopy confirms progressive nickel oxide and carbonaceous contamination, correlating with contact resistance trends that exhibit multi-phase behavior. Subsurface analysis reveals critical structural damage at mid-life cycles, emphasizing the importance of preventive maintenance. The findings advance understanding of wear mechanisms in Ag–Ni contacts and provide insights into optimizing their service life in industrial switching applications.
Stasac et al. (Tue,) studied this question.