Abstract:
An investigation of the DC load current effect on the corrosion behavior of copper contact materials in a neutral salt spray environment was conducted. Corrosion behavior under different load currents was assessed through corrosion rate measurements (via mass loss and electrochemical reduction methods) and contact resistance analysis. The results show that after 168 h of neutral salt-spray corrosion, the copper coupons exhibited similar macroscopic morphology at currents ranging from 0 to 5 A, characterized primarily by reddish-brown corrosion products. SEM observations revealed discontinuous punctate corrosion products distributed across the surface. At a current of 10 A, a greater amount of green rust appeared on the copper surface, with SEM observation revealing that the surface was covered by patchy, punctate corrosion products. When the current increased to 20 A, massive green corrosion products developed, with the corrosion products exhibiting noticeable aggregation and stacking. The EDS analysis results indicated that as the current increased, the copper content on the copper coupon surfaces decreased, while the oxygen and chlorine contents increased. The corrosion rate and contact resistance of copper showed no significant change at currents of 0-5 A, but increased markedly at 10 A and 20 A. Direct load current promotes the corrosion of copper, with this enhancing effect being more pronounced at higher current levels.