Modeling and Experimental Verification of Material Welding Characteristics for Low Current Switching Devices

Material welding failure considerably influences the electrical lifetime and reliability of low current switching devices. However, relevant studies on methods for calculating the threshold welding current and welding area under milli-Newton scale load forces are very limited. In this paper, the welding characteristics of metal material, including the threshold welding current, welding area and welding force are studied by using theoretical calculations and experiments. The comparison between the theoretical calculation and experimental results shows the accuracy of the built model. Further, the effects of mechanical load force and load current on welding force and welding area of representative metal materials are investigated. It is found that the anti-welding ability of metal materials depends not only on the exerted load force and current, but also the electrical resistivity, the thermal conductivity, the tensile strength, and the melting temperature of the materials.