Multi-Walled CNT (MWCNT) are synthesized on a silicon wafer and sputter coated with a gold film. The planar surfaces are mounted on the tip of a piezo-electric actuator and mated with a gold coated hemispherical surface to form an electrical contact. These switching contacts are tested under conditions typical of MEMS relay applications; 4V, with a static contact force of 1mN, at a low current between 20-50mA. The failure of the switch is identified by the evolution of contact resistance which is monitored throughout the switching cycles. The results show that the contact resistance can be stable for up to 120 million switching cycles, which are 106 orders of higher than state-of-the-art pure gold contact. Bouncing behavior was also observed in each switching cycle. The failing mechanism was also studied in relation to the contact surface changes. It was observed that the contact surfaces undergo a transfer process over the switching life time, ultimately leading to switching failure the number of bounces is also related to the fine transfer failure mechanism.

Novel contact materials such as extrinsic conducting polymers can improve contact performance and enable device miniaturisation. This paper presents an investigation of conducting polymer materials used to minimise the effect of fretting slip at the contact interface of connector terminals. Initial experimental studies are presented and a mechanical model is used to describe the polymer interface slip and stick characteristics. For fretting to be minimised the polymer must be sufficiently elastic, with a high coefficient of friction with the contacting terminal, and a sufficient normal force to ensure no slip. Experimental studies of a polymer-tin interface are conducted to characterise contact resistance performance under fretting conditions. A resistance model of the polymer interface is developed.

A gold coated carbon nanotubes composite was used as a contact material in Micro-Electrical-Mechanical-System (MEMS) switches. The switching contact was tested under typical conditions of MEMS relay applications: load voltage of 4 V, contact force of 1 mN, and load current varied between 20-200 mA. This paper focuses on the wear process over switching lifetime, and the dependence of the wear area on the current is discussed. It was shown that the contact was going to fail when the wear area approached the whole contact area, at which point the contact resistance increased sharply to three times the nominal resistance.

This paper presents a review of volumetric erosion studies applied to electrical contacts. The numerical methods presented are generic and could equally be applied to a number of areas where surfaces have been eroded or damaged. Equally there is no scale limitation of the surfaces to which the numerical methods can be applied. The paper starts with an introduction of the issues associated with the measurement of contact erosion, and then presents a summary of various hardware system for making 3D measurements of surfaces such as electrical contacts. This is followed by a review of the generic form fitting methods and also volume calculation methods. The paper concludes with a review of results taken from a test system for contact studies and from contact samples taken from commercial relays.