电连接器插针损伤失效分析

Failure Analysis on Damage of Pin of Electrical Connector

自动脱落分离电连接器在系列电性能测试后,外观检查发现分离插头一枚供电插针端部损伤,综合运用多种检测分析手段对损伤插针及相关部件宏微观形貌、金相组织以及成分进行观察分析,并开展短接模拟试验和比对分析。结果表明:插针损伤模式为电损伤,电弧放电导致针顶端部金属发生熔融、溅射,壳体内壁形成电弧烧蚀积瘤,分离测试时受人工抑制影响,致使插针与壳体绝缘间隙减小,从而极间介质击穿造成击穿放电。

After electrical test,one pin of the separate plug of an automatically-separating electrical connector was found to have been damaged at the end. In order to find out the failure cause,macro and micro observation,microstructure examination,chemical composition analysis and discharge simulation test were carried out. The results show that the failure mode of the pin is electrical damage. Arc discharge led to molting and sputtering of the pin tip metal. Arc damage also occurred at the inner wall of shell,causing accumulative burl. As a result,the clearance between the pin and the shell decreased and the media between the pin and the shell resulted in breakdown discharge.