Understanding Fretting Corrosion in Ruggedized Backplane Connectors

This white paper discusses fretting corrosion in ruggedized backplane connectors, which are essential in high-reliability applications such as aerospace and defense. The document outlines the causes of fretting corrosion, primarily due to micro-movements at contact points caused by vibration, thermal cycling, and mechanical shocks. It explains how these factors lead to wear and degradation of connector surfaces, ultimately resulting in increased electrical resistance and potential connector failure. The paper also presents various solutions to mitigate fretting corrosion, including increasing contact force, lubrication, mechanical locking mechanisms, and regular maintenance. Additionally, it details traditional contact technologies and introduces the Hypertac® Hyperboloid contact system by Smiths Interconnect, which is designed for harsh environments and offers enhanced reliability. The Hypertac® contact system features multiple redundant contact points, providing a low-resistance electrical path and a high current rating, making it suitable for demanding applications.