We propose a fine structure imaging for the surface and its inside of solid material such as coated drill bits with TiN (Titanium Nitride). We call this method i-MSE (innovative MSE) since the fine structure is visualized with a local mechanical strength (the local erosion rate) which is obtained from a set of erosion depth profiles measured with Micro Slurry-jet Erosion test (MSE). The local erosion rate at any sampling point is estimated from the depth profile using a sliding window regression and for the rest of the 2-dimensional points it is interpolated with the mean value coordinate technique. The interpolated rate is converted to a 2D image (i-MSE image) with a color map. The i-MSE image can distinguish layers if the testing material surface is composed of coats which have different resistance to erosion (erosive wear), while microscopic image such as SEM (Scanning Electron Microscope) and a calotest just provides appearance information, not physical characteristics. Experiments for some layered specimens show that i-MSE can be an effective tool to visualize the structure and to evaluate the mechanical characteristics for the surface and the inside of solid material.

The micro-mechanism of molten pool and metal droplet sputtering are significant to the material erosion caused by breaking or making arcs especially for high-power switching devices. In this paper, based on Navier-Stokes equations for incompressible viscous fluid and potential equation for electric field, a 2D axially symmetric simplified hydrodynamic model was built to describe the formation of the molten metal droplet sputtering and molten pool under arc spot near electrode region. The melting process was considered by the relationship between melting metal volumetric percentage and temperature, a free surface of liquid metal deformation was solved by coupling moving mesh and the automatic re-meshing. The simulated metal droplet sputtering and molten pool behaviors are presented by the temperature and velocity distribution sequences. The influence mechanism of pressure distribution and heat flux on the formation of molten pool and metal droplet sputtering has been analyzed according to the temperature distribution and sputtering angles. Based on the simulation results, we can distinguish two different models of the molten metal droplet sputtering process: edge ejection and center ejection. Moreover, a new explanation is proposed based on calculated results with arc spot pressure distribution in the form of both unimodal and bimodal. It shows that the arc spot pressure distribution plays an important role in the metal droplet ejected from molten pool, the angle of the molten jet drop can be decreased along with the increment of the arc spot pressure.

Break arcs are rotated with a radial magnetic field formed by a permanent magnet embedded in a fixed contact. The break arcs are generated in a 48VDC resistive circuit. The circuit current is 10A when the contacts are closed. The polarity of the fixed contact in which the magnet is embedded is changed. The rotational radius and the difference of position between the cathode and anode spots are investigated. The following results are obtained. The cathode spot is moved more easily than the anode spot by the radial magnetic field. The rotational radius of the break arcs is affected by the Lorentz force that is caused by the circumferential component of the arc current and the axial component of the magnetic field. The circumferential component of the arc current is caused by the difference of the positions of the rotating cathode and anode spots.

Many DC commutator motors are widely used in automobiles. In recent years, as compact and high output DC motors have been developed due to advanced technology, the faster the rotational speed is required and the commutation arc causes a high rate of wear/erosion of brush and commutator. Therefore, it is important how the motor speed influences commutation phenomena such as arc duration, residual current and erosion and wear of commutator and brush in order to achieve high reliability and extensive lifespan. In this paper waveforms of commutation voltage and current are measured at the rotation speed of 1000 to 5000min-1and the relation between rotation speed and arc duration / residual current is obtained. In addition long term tests are carried out at the rotation speed of 1000 to 5000min-1 the change of arc duration and effective commutation period is examined during the test of 20hours. Further, brush wear is evaluated by the difference of brush length between before and after test. Consequently, it can be made clear that as the speed increases, the effective commutation period decreases and the arc duration is almost same at the speed up to 3000min-1 and is around 42µsec.

Break arcs are rotated with the radial magnetic field formed by a magnet embedded in a fixed cathode contact. The break arcs are generated in a 48VDC resistive circuit. The circuit current when the contacts are closed is 10A. The depth of the magnet varies from 1mm to 4mm to change the strength of the radial magnetic field for rotating break arcs. Images of break arcs are taken by two high-speed cameras from two directions and the rotational motion of the break arcs is observed. The rotational period of rotational motion of the break arcs is investigated. The following results are obtained. The break arcs rotate clockwise on the cathode surface seen from anode side. This rotation direction conforms to the direction of the Lorentz force that affects to the break arcs with the radial magnetic field. The rotational period gradually decreases during break operation. When the depth of magnet is larger, the rotational period becomes longer.

Cu-Mo alloy carries forward not only high electrical conductivity and high thermal conductivity from Cu but also high hardness from Mo, which makes it a promising potential application in electrical contact fields. In this paper, arc characteristic and erosion characteristic of Cu-Mo contacts are studied with a bridge-type contact high speed break mechanism on DC270 V/200 A load condition. And in each experiment group, 2500 times break operations are carried out. During every break operation, a high-speed AD card is used to record voltage and current signal of the arc, a high-speed camera is applied to record arcing process, and the temperature of contacts and arc are acquired by thermocouple and spectrometer, respectively. The mass and contact resistance of contacts are measured before and after every group experiment. Besides, the photograph of contact surface is taken by SEM to help analyze the erosion characteristic. The comparison between Cu-Mo contacts and Cu contacts indicates that although Cu contacts have a better electrical conductivity and thermal conductivity, Cu-Mo contacts can decrease the temperature of arc to prevent thermal breakdown, and they are also harder to be ablated and have a longer life span.

As VLSI process node continue to shrink, chemical mechanical planarization (CMP) process for copper interconnect has become an essential technique for enabling many-layer interconnection. Recently, Edge-over-Erosion error (EoE-error), which originates from overpolishing and could cause yield loss, is observed in various CMP processes, while its mechanism is still unclear. To predict these errors, we propose an EoE-error prediction method that exploits machine learning algorithms. The proposed method consists of (1) error analysis stage, (2) layout parameter extraction stage, (3) model construction stage and (4) prediction stage. In the error analysis and parameter extraction stages, we analyze test chips and identify layout parameters which have an impact on EoE phenomenon. In the model construction stage, we construct a prediction model using the proposed multi-level machine learning method, and do predictions for designed layouts in the prediction stage. Experimental results show that the proposed method attained 2.7∼19.2% accuracy improvement of EoE-error prediction and 0.8∼10.1% improvement of non-EoE-error prediction compared with general machine learning methods. The proposed method makes it possible to prevent unexpected yield loss by recognizing EoE-errors before manufacturing.

Break arcs are generated in a DC48V and 12A resistive circuit. Silver electrical contacts are separated at constant opening speed. The cathode contact surface is irradiated by a blue LED. The center wavelength of the emission of the LED is 470nm. There is no spectral line of the light emitted from the break arcs. Only the images of contact surface are observed by a high-speed camera and an optical band pass filter. Another high-speed camera observes only the images of the break arc. Time evolutions of the cathode surface morphology being eroded by the break arcs and the motion of the break arcs are observed with these cameras, simultaneously. The images of the cathode surface are investigated by the image analysis technique. The results show that the moments when the expanded regions on the cathode surface are formed during the occurrence of the break arcs. In addition, it is shown that the expanded regions are not contacted directly to the cathode roots of the break arcs.

Break arcs are generated in a DC48V resistive circuit. The circuit current is varied from 1A to 6A. The contact resistance distribution on the anode surfaces eroded by break arcs is investigated. The following results are shown. When the current is 2A, 3A and 6A, the contact resistance at the center region of the anode surface is higher than that around the center region. The contact resistance around the center region decreases with the decrease of the circuit current. When the current is 1A, the contact resistance is very low at all positions on the contact surface. The lower contact resistance may be caused by the occurrence of the short arc that is extinguished in the metallic phase arc.

Break arcs are rotated by the radial magnetic field formed by a magnet embedded in the pipe-shaped cathode. The arcs are generated in switching a DC42 V resistive circuit. The closed contact current varies from 5 A to 21 A. The curvature of the anode surface is varied to study the dependence of the arc length and the positions of the break arcs in the contact gap. The following results are obtained: (i) as current decreases, there is more difference in arc duration among different curvatures; (ii) as current decreases, the arc duration decreases with decrease of the radius of curvature; (iii) in each contact curvature, the anode spots region is located nearer to the center axis than the cathode spots region; (iv) the arc length just before arc extinction is independent of the curvature of the contacts.

Using a self-developed ASTM test system of contact material electrical properties under low voltage (LV), small-capacity, the current-frequency variable and a photoelectric analytical balance, the electric performance comparison experiments and material weighing of silver-based electrical contact materials, such as silver/tungsten and silver/cadmium oxide contact materials, are completed under LV, pure resistive load and small current at 400 Hz/50 Hz. The surface profiles and constituents of silver/tungsten contact material were observed and analyzed by SEM and EDAX. Researches indicate that the form of the contact material arc burnout at 400 Hz is stasis, not an eddy flow style at 50 Hz; meanwhile, the area of the contact burnout at 400 Hz is less than that of 50 Hz, and the local ablation on the surface layer at 400 Hz is more serious. Comparing the capacities of the silver-based contact materials with different second element such as CAgW50, CAgNi10, CAgC4 and CAgCdO15 at 400 Hz, no matter what the performances of arc erosion resistance or welding resistance, it can be found that the capacities of the silver/tungsten material is the best.

Break arcs are rotated with the radial magnetic field formed by a magnet embedded in the fixed contact. They are generated in a DC42 V resistive circuit. The circuit current when the contacts are closed varies from 5 A to 21 A. The strength of a radial magnetic field for rotating break arcs changes. Arc duration is investigated. Then rotational frequency, arc length and Lorentz force when the periodic rotation of break arcs starts are analyzed to investigate the conditions required to rotate break arcs. The following results are obtained. The arc length L when the rotational motion of the break arc starts is almost constant at a constant magnetic flux density with an increase in circuit current. The arc length L decreases with an increase in the magnetic flux density of the radial magnetic field. The rotational motion of break arcs starts when the arc length L reaches a certain value determined by magnetic flux density. Rotational frequency and Lorentz force increase linearly with an increase in circuit current.

The paper presents the state of knowledge about thermal-erosion processes in contacts of low-voltage switching devices for power engineering on switching currents under short-circuit conditions. The graphical models of the short arc and the distribution of arc power introduced into contacts are shown. The method for measurements of a contact temperature during an electric discharge has been elaborated. The obtained test results are presented, i.e. changes of a contact temperature as a function of arc parameters such as current, energy, and integral ∫idt. The tests have shown that a "break point" exists on the curve expressing the relationship between a temperature rise and arc parameters in the range of high currents. The location of this point is dependent on a diameter of contacts and a value of current, and is associated with thermal energy delivered to electrodes. It has been observed that for each diameter of contacts there exists such value of an energetic quantity of arc (current, ∫idt, energy), at which diameters of arc roots are the same as a contact diameter. Above this value, the shape of a curve is changed. The obtained results explain and confirm the discontinuity of a curve expressing a contact arc erosion as a function of current, which was observed earlier by the other research workers.

The paper presents a method for testing transport of composite contacts materials under electrical arc conditions at high currents and for polarized electrodes. Tests and the discussion of results were carried out for silver-metal, silver-metal oxide and silver-tungsten carbide contact materials. Additionally, tungsten electrode was used as the second contact which was either cathode or anode. Spectrometric analysis of arc erosion components transported onto the second electrode and into the surroundings was carried out.

The paper presents a computer program for the calculation of contact mass loss in the case of evaporation, ablation and melting. It makes use of theoretical mathematical equations previously published by a lot of researchers. For the purposes of the program, an expert system algorithm was designed. The paper presents results obtained by means of the proposed program for silver, tungsten and copper.

The sputter erosion of arcing contacts is a very complex phenomenon, which is determined by the interaction between electromagnetic force, heat conduction and surface tension of liquid metal. A new model for evaluating the sputter erosion of electrodes is described in this paper, which is based on the electromagnetic forces against the molten pool, flowing velocity, kinetic energy and the surface tension of the molten pool. Erosion tests on AgSnO2, AgNi10 and AgNi0.15 contacts under the loads of resistance, lamp and inductance respectively at 14 VDC have been carried out. Experimental results indicate good agreement with the model's simulation. The model shows how the current and density, specific heat and other parameters of material affect the erosion rate.

We initiated development of our own data processing software for laser microscope data with C# language. This software is provided with volume calculation function of a target portion, based on a new calculation algorithm that can precisely handle the volume calculation of the portion located on a tilted surface or on a distorted surface. In this paper, this algorithm and some exemplary results obtained thereby, as well as some further development aims, are briefly described.

The three major failures of electrical contacts for automotive relay applications are: contact welding (or contact sticking), high contact resistance and severe contact erosion due to switching arcing. With the demand of high power and multiple functions of automotive vehicles, the switching current has be dramatically increased, it results in higher failing rate, in particular for contact welding. On the other hand, the miniaturization of electromechanical relays has lead to the reduction of mechanical spring force. This not only results in the earlier contact welding but also makes the relay more susceptible to the contact resistance and arc erosion failures. This paper is a review of most recent studies on these three failure aspects. It describes the progress in the understanding of contact welding caused by short arcing and high contact resistance due to contamination of particles and films in relay manufacturing process and also it review the material transfer due to switching arcing. At the end, the brief considerations of electromechanical relays used in 42 volts have also been given.

The paper reviews methods for the measurement and analysis of high precision surfaces. A number of measurement techniques are discussed with the emphasis on the application of con-focal methods. The various techniques are compared in terms of measurement times, data density, and the ability to detect near vertical surfaces, and steps. The two sensing methods discussed are the auto-focus laser method and the white light methods. Particular applications considered are in the measurement of eroded electrical contact surfaces, spherical and near spherical surfaces, and MEMS. The particular emphasis here is on the metrology of such surfaces and devices and methods for the assessment of complex micro-machined surfaces. The paper points to a number of directions for improved metrology and discusses these in the context of the application given.

A new scheme for evaluation of shapes of pips and craters formed by arc discharges on electrical contact surfaces is proposed. Measuring a height of a pip or a depth of a crater as well as an average diameter thereof with a scanning laser microscope and then putting a plot having the measured values as its vertical and horizontal coordinates enable us to numerically and briefly evaluate shapes of those pips and craters on arc-damaged contact surfaces. Some exemplary results obtained by this evaluation scheme are presented here.