Evaluation of materials used for coatings of electrical connectors used in the electrical harness of passengers cars

Abstract

Automotive electrical connectors are the essential components of a wiring harness. They are typically made of copper, which has excellent electrical conductivity. Due to the limited corrosion resistance of pure copper, connectors are often coated with other metals. In this paper, the qualities of coatings made of gold and tin are investigated and compared. The samples were examined by a metallographic microscope and scanning electron microscope (SEM). The examination revealed uneven thickness, delamination of the coatings, and issues with the preparation of the core material for coating. Numerous burrs and irregularities were observed. Selected samples were examined in salt solution to test their corrosion resistance. Even though gold is a noble metal and its electrochemical potential is higher, the tin coating was more resistant to corrosion.