Arc occurrence rates were measured for Ag contacts in DC resistive and inductive load circuits. In inductive load conditions, arc occurrence rates in general came close to 100% at around 0.4 A, the conventional minimum arc current level of Ag. In resistive load conditions, the similar results were obtained with 30 V, while arc occurrence rates close to 50% were still obtained at around 0.4 A with 14 V and 10 V. Careful attention should be paid to the term "minimum arc current" to avoid misinterpretation thereof.

Arc occurrence rates are measured for Ag and Pd contacts operated in a DC resistive load circuit. Based on the obtained results, it is confirmed that arc certainly occurs at current levels lower than the conventional minimum arc current value for each of the tested contact materials. Arc occurrence rate in general comes close to 100% at the conventional minimum arc current level. Accordingly, careful attention should be paid to use of the term "minimum arc current" in order to avoid misinterpretation thereof.

Arc discharge between electrodes of relays and switches often causes contact surface damage through material transfer and arc erosion. Especially, material transfer sometimes occurs and brings serious failure even under lower load that is quite smaller than the minimum arc current value of contact material. In this paper, contact surface configuration, material transfer, and arc erosion characteristics of Ag and AgPd 60 contacts were experimentally studied after 0.5 or 1 million switching operations at various load levels. The followings can be made clear. Firstly, it was confirmed that the arcs and material transfer occurred even under such current that was lower than the minimum arc current. Therefore, the definition of the arc occurrence boundary current was newly determined. Secondly, the relation between load conditions (current and power supply voltage) and contact surface configuration (craters and pips) caused by material transfer was studied. The arc erosion behaviors of tested samples could be classified into two types: material transfer type and wear-out type. As one of the primary factors of transition from the former type to the latter one, contact activation was considered. The influences of load conditions and organic gas emitted from relay structure on arc characteristics was experimentally examined. The results indicated that load current greatly influenced the amount of material transfer and that power supply voltage affected the occurrence of the wear-out type significantly. The activation behavior of the contact surface could be found through observing the bridge voltage waveform.