Analysis of high contact resistances associated with hermetic and lightning arrestor connectors

Contact resistances of greater than 40 milliohms have been associated with hermetic connectors and lightning arrestor connectors (LAC) during routine testing. Empirical analysis demonstrated that the platings could be damaged within several mating cycles. The oxides that formed upon the exposed copper alloy had no significant impact upon contact resistance when the mated contacts were stationary, but effectively disrupted continuity when the mating interfaces were translated. The stiffness of the pin contact was determined to be about five times greater than the socket contact. As the pin contact engages the socket, therefore, the socket spring member deflects and the pin does not deflect. Hence, the pin contact could easily remain centered within the socket cavity in a mated condition, contacting the hemispherical spring at a localized point. Thus the only avenue for electrical conduction is between two contacting curved surfaces -- the pin surface and the socket contact dimple surface. This scenario, coupled with the presence of corrosion products at the contacting interface, presents the opportunity for high contact resistances.