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Deformation Behavior of Asymmetric Direct Laser Interference Patterning Structures on Hot-Dip Tinned Copper.

Silas Schütz¹, Sebastian Suarez¹, Yannik Bautz¹

¹Department of Materials Science and Engineering, Saarland University, 66123 Saarbrücken, Germany.

Materials (Basel, Switzerland)

|December 11, 2025

Summary

This study explores how surface microstructures on hot-dip tinned copper affect mechanical contact. Tailored surface patterns and aging influence load capacity and deformation, crucial for electrical interface optimization.

Keywords:

asymmetry contact mechanics indentation laser structuring

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Area of Science:

Materials Science
Surface Engineering
Tribology

Background:

Optimizing electrical and mechanical interfaces relies on understanding contact mechanics.
Surface structuring significantly impacts the performance of these interfaces.

Purpose of the Study:

Investigate the mechanical contact behavior of hot-dip tinned copper surfaces.
Analyze the influence of Direct Laser Interference Patterning (DLIP) on surface properties.

Main Methods:

Fabricated microstructures with varying periodicities and tilt angles on tinned copper.
Characterized surfaces using confocal laser scanning microscopy.
Performed indentation testing and employed finite element simulations for mechanical analysis.

Main Results:

Surface periodicity, tilt angle, and aging significantly affect load-bearing capacity and deformation.
Intermediate periodicities (7.5 µm) at 0° tilt showed highest plastic deformation susceptibility in as-received samples.
Aged samples exhibited enhanced mechanical stability due to the formation of a harder Cu 6 Sn 5 surface layer.

Conclusions:

Tailored surface morphology and material selection are critical for designing effective structured contact surfaces.
Findings provide insights for optimizing electrical applications through controlled surface engineering.
Understanding deformation behavior is key to improving the reliability of electrical contacts.