Failure Mode The majority of connector failures result in intermittent connections or open contacts:
High temperatures can also cause failure in connectors, resulting in an "avalanche" of failures – ambient temperature increases, leading to a decrease in insulation resistance and increase in conductor resistance; this increase generates more heat, and the cycle repeats. Fretting (so-called dynamic corrosion) is a common failure mode in electrical connectors that have not been specifically designed to prevent it, especially in those that are frequently mated and de-mated. Surface corrosion is a risk for many metal parts in connectors, and can cause contacts to form a thin surface layer which increases their resistance, thus contributing to heat buildup and intermittent connections. However, remating or reseating a connector can alleviate the issue of surface corrosion, since each cycle scrapes a microscopic layer off the surface of the contact(s), exposing a fresh, unoxidised surface. |