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Fretting wear remains a critical reliability challenge in electrical contacts, leading to increased contact resistance and intermittent failures. While electroplated gold (EPG) has been the standard finish for noble metal contacts, its non-uniform microstructure can adversely affect electrical performance and reliability. This has motivated the exploration of electroless gold (EG) as a potential substitute.

CALCE's comparative study evaluates these gold finishes under fretting conditions, focusing on their electrical and tribological performance. EG’s contact performance was compared with EPG’s, supported by data on contact resistance evolution, wear mechanisms, and contact lifetime. Advanced surface and material characterization techniques, including confocal laser scanning microscopy, nanoindentation, and atomic force microscopy, provide insights into wear mechanisms, coating properties, and surface topography evolution. We also discuss standard practices for characterizing coating hardness and thickness, which is critical for material selection. This research provides actionable insights for implementing EG finishes in connector applications, balancing cost, performance, and reliability.

About the Presenters:

Soma Roy is a doctoral student in Mechanical Engineering at the University of Maryland, where she conducts research under the guidance of Dr. Michael H. Azarian. Her work focuses on tribology of contact interfaces, with an emphasis on improving the performance of electronic components through advanced lubrication and material solutions. Her contributions have been recognized with a scholarship from the Philadelphia Section of the STLE (Society of Tribologists and Lubrication Engineers). Before joining UMD, Soma earned her bachelor’s degree in Mechanical Engineering from the Bangladesh University of Engineering and Technology (BUET).

Michael Azarian is a Research Scientist at the Center for Advanced Life Cycle Engineering (CALCE) at the University of Maryland. He holds a Masters and Ph.D. in Materials Science and Engineering from Carnegie Mellon University and a Bachelor's degree in Chemical Engineering from Princeton University. His research is focused on the analysis, detection, prediction, and prevention of failures in electronic and electromechanical products. He has over 150 publications on electronic packaging, component reliability, prognostics and health management, and tribology. He holds 6 U.S. patents. Prior to joining CALCE in 2004, he spent over 13 years in the data storage, advanced materials, and fiber optics industries.