We report the observation of two distinct modes of rate-dependent behavior during contact cycling tests. One is a higher pull-off force at low cycling rates and the other is a higher pull-off force at high cycling rates. Subsequent investigation of these contacts using scanning electron microscopy ͑SEM͒ demonstrates that these two rate-dependent modes can be related to brittle and ductile separation modes. The former behavior is indicative of brittle separation, whereas the latter accompanies ductile separation. Thus by monitoring the rate dependence of the pull-off force, the type of separation mode can be identified during cycling without interrupting the test to perform SEM. © 2008 American Institute of Physics. ͓DOI: 10.1063/1.2967855͔Operation of a microelectromechanical system switch requires closing and opening of the microcontacts over many billions of contact cycles. 1 During this process the contact resistance and contact adhesion change, often leading to failto-close or fail-to-open switch failures. In order to study the evolution of microcontacts, we developed a scanning probe microscope ͑SPM͒ based contact test station. 2 Contact testing was performed between hemispherical contact bumps ͑microfabricated on very stiff SPM cantilevers͒ and planar substrates. Both the bumps and substrates were coated with the contact test material. Using this contact tester, we have studied different contact materials 3 and contact adhesion. 4 Microcontacts may separate in brittle or ductile modes. 5 In the brittle mode ͓Fig. 1͑a͔͒, rupture occurs abruptly with little, if any, plastic deformation. In the ductile mode ͓Fig. 1͑b͔͒, rupture occurs more gradually with significant plastic deformation. In previous studies, 2-4 the type of separation mode ͑ductile or brittle͒ which occurred could only be identified by scanning electron microscopy ͑SEM͒ observation and not during the cycling test.Depending on the separation mode, the surface morphology of the microcontacts can change, eventually leading to large changes in the pull-off force ͑i.e., the force needed to separate the contacts͒. 4,5 In this paper, we report our observation that the magnitude of the pull-off force depends on the cycling rate, and that this rate dependence is related to the separation mode. This behavior allows the separation mode to be identified during testing without SEM observation. 6 To study the rate dependence of the pull-off force, a 250 nm gold thin film was sputtered on the hemispherical bump ͑15 m radius of curvature͒ of an especially fabricated very stiff test cantilever ͑K Х 10 4 N / m͒ and also on the mating planar substrate. The tests were performed in laboratory air with a relative humidity of 30%-40%. The cycling tests use a small piezoactuator in addition to those in the SPM to achieve a high cycling rate. The pull-off force was measured using the SPM.The pull-off forces at two cycling rates ͑0.5 and 300 Hz͒ were compared by suddenly switching from one frequency to the other. The maximum contact force was controlled at 200 N during...