28th International Conference on Electric Contacts, 6-9 June 2016, Edinburgh Performance evaluation of the new Gold Capped Silver (GCS) plating system for connectors contact applications Antoine Fares Karam Doyle Anderson, Jeffrey Toran Global Plating Engineering Amphenol FCI, FCI Besancon SA Besançon, France antoine.fares-karam@fci.com Global Engineering Services Amphenol FCI, FCI USA LLC Etters, PA, USA jeffrey.toran@fci.com The Gold Capped Silver (GCS) reel-to-reel plating system is developed to replace gold and gold flash over palladium-nickel (GF-PdNi or GXT) plating in connector applications to take advantage of silver’s technical properties to enhance performance of power connectors and/or provide an economical advantage for signal connectors. GCS plating is a silver plating based system that uses a matte hard silver as the foundation layer. A gold flash layer protects the silver plating layer against tarnishing, sulfidation and oxidation which may lead to increased electrical contact resistance. The top layer is either a special PolyAlphaOlefin (PAO) or a PerFluoroPolyEther (PFPE) highperformance lubricant to ensure good tribological performance. The GCS plating system has improved performance compared to conventional silver plating but with much lower silver plating thickness and it can be applied to power and signal connectors. Connectors plated with GCS are better for applications requiring higher number of mating and un-mating cycles than typical soft silver plating, which has serious limitations. This paper presents detailed investigations and characterizations of the GCS plating system and describes its application to several different types of connectors. Thorough performance and surface analysis data are provided to demonstrate the stability, reliability and robustness of this plating system. Keywords— GCS; silver; gold; electroplating;connectors I. INTRODUCTION A. Bacgkround “Gold plating” and “Gold Flash over Palladium-Nickel alloy” (GF-PdNi or GXT®) are historically the most widely used finishes in the electronic connector industry for the past 30 years, while the automotive connector industry uses conventional Tin plating. Silver plating usage in this field has been moderate for several decades, but since the early 1990’s silver has become more favored by the increased use of automotive power connectors. Silver enjoys a number of technological benefits as it is one of the best electrical and thermal conductors, which makes it the “metal of choice” for a variety of electrical end-uses, including switches and connector contacts. Consequently silver has been used for years in both high and lower current separable connector power applications. Nevertheless, the placement of silver on electronic components and connector Fares Karam 81 products has always been a source of concern due to silver tendency to migrate between isolated conductors (silver migration), leading to unintended electrical short-circuits [1], as well due to silver sensitivity to sulfidation (formation of Ag2S products on the surface) in the presence of sulfur contaminant compounds, in a liquid or gaseous phase, in its near environment. The migration of silver is driven by its propensity to undergo an oxidation reaction in the presence of moisture and an electric field [2,3]. Silver-sulfides cause the typical ‘black’ color tarnishing of silver plated surfaces. This surface reaction takes away from the beauty of the silvery colored surface, however it does not severely degrade performance till failure, as the tarnish compounds are electrically conductive [4]. Evidently this is still critical for power connectors as Silver sulfide electrical resistivity is nearly 17.3 Ω.cm which is much more resistive than Silver (1.59 mΩ.cm). Despite these two drawbacks, more and more applications are using silver plating as a lower or moderate cost connector finishing coating in automotive connectors, electrical components and a limited number of electronic connectors where Silver is very suitable for signal connectors with higher normal force and lower durability requirements. Plating chemical suppliers have developed many anti-tarnishing agents to protect Silver surfaces against corrosion, sulfidation and oxidation to mitigate the aforementioned two risks. These chemical solutions allow silver plated based applications to increase, although they are not yet the best solutions and further improvements need to be achieved [5,6] in order to make their performance equivalent to inorganic anti-tarnish or protection layers [7]. B. Current approaches for application of Ag as plating for connectors Beside the usage of the organic or inorganic anti-tarnishing systems, other alternative approaches, such as alloying silver, are used to make Silver plating acceptable in specific applications. We can find Silver-Palladium alloys where it is demonstrated that a minimum of 10% to 15% Pd is sufficient to greatly retard silver migration and inhibit sulfidation reaction for a long time [8,9,10]. Silver-Tin alloys (Sn content between 10% and 30%) were also developed with the same objectives [11,12,13], but most of these alloys, including 4.4 28th International Conference on Electric Contacts, 6-9 June 2016, Edinburgh recently developed and commercialized chemistries, are not really convenient for high speed reel-to-reel connector terminals plating. These alloyed silver plating solutions have not shown, yet, wide commercial use due to their complex plating baths formulations, the difficulties to achieve reasonable plating line speed, the weak stability of the plating process itself or the cost issues in some cases. Other (simpler) approaches have been utilized such as using lubricated conventional Silver coatings [14] for power connectors, or a lubricated special nanocrystalline hard silver system [15] for power and signal connectors. The objective of this paper is to present a new approach to enlarge the usage of silver based coatings for electrical contact terminals, the Amphenol-FCI developed Gold Capped Silver or GCS™ plating system. II. GOLD CAPPED SILVER (GCS™) A. Brief description of the GCS™ plating system We have developed the GCS™ plating system to replace Gold and Gold Flash over Palladium-Nickel (GF-PdNi or GXT®) plating in some connector applications to take advantage of Silver’s technical properties to enhance performance of power connectors and/or provide an economical advantage especially for signal connectors. As represented in Fig. 1, the GCS™ plating system is a silver plating based system that uses a matte hard silver replacing conventional soft silver. A gold flash layer protects the silver plating layer against tarnishing and operates partially as a solid lubricant layer. It avoids silver layer oxidation and sulfidation which usually leads to increased electrical contact resistance. The top layer is a special polyalphaolefin (PAO) or a PerFluoroPolyEther (PFPE) high-performance lubricant and is conferring a self healing function to this protection layer which ensures that the wear track during mating/un-mating cycles is always lubricated and protected. The Nickel underplating is a nanocrystalline highly corrosion resistant layer. B. Technical Background of the GCS™ plating systems Plating gold over silver has been known for decades in the jewelry industry and it is even regulated in many countries for quality purposes [16]. In the field of passive electronic components, plating gold over silver has been mainly used for switches [17,18] where Gold, Silver and Gold over Silver are the three most common contact materials. Gold plating is usually dedicated for low current and/or low voltage switches where any surface oxidation or tarnishing cannot be tolerated. Conventional soft Silver plating is usually used for switches and circuits where an electrical arc is expected. Gold plating over Silver is typically used in double pole switches applications in order to obtain some of the advantages of both materials; added to the fact that gold will remain intact and will provide tarnish free contacts for high reliable long term switching [19,20]. In summary, Gold plating over Silver plating finishes have been used for several years in some passive electronic components [21] but not yet used for separable interfaces such as connectors which have completely different performance requirements in terms of durability cycling. Transposing the “Gold over Silver” process to connectors, as used currently in switches, does not work if it is not optimized and adapted properly. GCS™ is a performance optimized multi-layer plating system and the four layers are required to make the contact interface resistant to corrosion, sulfidation and ensure durability. Hereafter several detailed experimentation results, demonstrating the suitability of using the GCS™ system for both Power & Signal connector applications, are shown. III. EXPERIMENTAL Several characterization techniques are used to assess the properties of the GCS™ plating system. Fretting-Corrosion and Durability testing with continuous low-level electrical contact resistance (LLCR) measurements were made using Bruker UMT3 universal mechanical testers equipped with a mechanical reciprocating module and a separate piezzo module. A flat real connector header contact or a flat plated specimen were fixed on these lower modules. The upper module has a ball holder or a special hemispherical coupon with variable radius (between 0.8mm and 1.6mm) allowing to simulate different connector terminals receptacle geometries under different contact pressures. SIMS (Secondary Ion Mass Spectrometry) analyses were performed as qualitative and semi-quantitative composition elemental profiles in depth from the top surface down to the bulk of the silver plated layer. The used instrument is TOF-SIMS V equipped with one Bi gun (25 KV) and another Cs gun (2 KV). All the metallic hemispherical caps and flat substrates were made of the same phosphor-bronze copper base metal or the same high conductivity copper base metal as the tested real connectors. IV. Fig. 1 Fares Karam RESULTS A. Electrical Contact Resistance Tarnishing is a long–established challenge in the silver plating industry. Tarnishing is predominantly caused by airborne sulfur, which reacts with the surface of silver and Schematic representation of GCS plating system. 82 4.4 28th International Conference on Electric Contacts, 6-9 June 2016, Edinburgh produces black silver sulfide (Ag2S). This sulfide layer affects the plating’s excellent electrical properties. Unlike most other corrosion films, the growth of the silver sulfide layer is linear over time. When there is a thick enough layer of Ag2S and an enough high temperature, an additional process of thin filament growth (whiskers) begins [22]. In the GCS™ plating, the Gold flash layer is used to act primarily as an inorganic anti-tarnish film replacing organic post-treatments which cannot withstand 105°C or 125°C temperature ageing tests, nor typical three lead-free reflow cycles. In fact, it’s extremely detrimental for electrical contact resistance to use organic antitarnish agents beyond their operating thermal range as this will lead to decomposition of the organic layer and significant increase of resistance (Rc) at the terminal-contact interface [14]. Taking into consideration the typical electrical resistivity values for the mostly used plated deposits in connectors (see Table I) it is evident that both Gold and Silver exhibit excellent electrical conductivity and we would not expect, in theory, any electrical drawback when super-imposing these two layers. TABLE I. ELECTRICAL RESISTIVITY OF TYPICAL MATERIALS AND PLATED DEPOSITS ON CONNECTORS CONTACTS Material Resistivity (mΩ.cm) 1.68 1.59 2.82 10.78 Copper (Cu) Silver (Ag) Aluminum (Al) Palladium (Pd) Material Gold (Au) Tin (Sn) Nickel PdNi (80/20) Resistivity (mΩ.cm) 2.44 10.91 6.99 ~9.5 to 11.5 Technical literature [23,24] demonstrates clearly that interdiffusion between Gold and Silver occurs, which will change the top layer composition and thus change the resistivity. Fig. 2 shows the Low level Contact Resistance (LLCR) variation according to normal load for a system consisting of a bronze hemisphere (see Fig. 3), coated with 0.76µm hard Gold, against a power type connector flat contact coated with 2.5µm freshly plated GCS™. The second flat contact was also plated with 2.5µm GCS but was subject to 12 days of thermal treatment at 105°C to accelerate silver-gold (AuAg) interdiffusion. Values are given for measurements without any “wipe” between hemispherical caps and flat samples to avoid removing any specific top layer formed due to interdiffusion, although in reality there is always at least one mating cycle, which is a more favorable case. 5 Varying the normal force between 0.2N and 5N for this Sphere-Flat system corresponds to varying the contact pressure between 300 MPa and 1000 MPa according to Hertz stress calculations. Fig. 3 Hemispherical caps and flat contact used for ECR testing It is important to note that reported electrical contact resistance (ECR) values include bulk-copper resistance due to the wiring configuration in the tribology equipment. The curves show that as plated GCS™ is slightly less resistive than the thermally aged GCS™ for the lower normal loads corresponding to lower contact pressures. These results are in agreement with technical literature describing that thermal ageing induces a faster interdiffusion rate between Silver and Gold leading to an alloy with higher resistivity [25]. Nevertheless, we can see clearly on Fig. 2 that both curves are overlapping quite quickly. The fact that the two GCS™ curves tend to have equivalent contact resistance values with increasing normal load (so with increasing contact pressure), suggests that interdiffused AuAg layer is very thin. Consequently, and except for the very low contact pressure interfaces, the superficial thin interdiffusion layer has minor influence on the system ECR. In other words, the AuAg interdiffusion layer is protecting the silver layer against tarnishing while having minimal impact on its ECR. In all cases we have always low ECR values which are suitable for all electronic connector applications and the slight increase in GCS™ resistivity is not significant. B. Validation of Gold and Silver interdiffusion on GCS™ plated power connectors We performed interdiffusion evaluations on High Power Edge Card connector (HPCE®). The connector contacts are GCS™ plated using a reel-to-reel plating line under industrial conditions and assembled. Connectors were mounted on test printed circuit boards and thermal ageing was conducted at 105°C up to 2000 hours. LLCR measurements were made every 500 hours. Fig. 4 shows the LLCR variations for the twelve different rows of the connector. We can see the maximum average LLCR increase is 0.3mΩ after 2000h while the maximum LLCR increase among all the individual values measured does not exceed 0.47 mΩ. 4.5 0.6 GCS 12 days 105 C Contact Ressistance Variation (mΩ) Contact Resistance (mΩ) 4 3.5 GCS as plated 3 2.5 2 1.5 1 0.5 0 0 1 2 3 4 5 0.5 0.4 0.3 0.2 0.1 0.0 0 6 GCS contact resistance variation acording to normal force Fares Karam 1000 1500 2000 Thermal Ageing of HPCE at 105 C (h) Contact Force (N) Fig. 2 500 83 Fig. 4 R01 R02 R03 R04 R12 R11 R05 R06 R07 R08 R09 R10 Contact resistance variation of GCS™ plated HPCE® connector according to thermal ageing 4.4 28th International Conference on Electric Contacts, 6-9 June 2016, Edinburgh It is important to note that for such type of power connector, the maximum allowed LLCR increase is 0.6mΩ. These low LLCR values prove the thermal stability of the GCS™ system from an electrical point of view and confirm that interdiffusion of Silver and Gold has minor impact on electrical characteristics of the GCS™ interface. C. Quantitative investigation of Gold and Silver interdiffusion in GCS™ plating system One of the most interesting methods to study the interdiffusion of Au and Ag is SIMS given its sensitivity and very low limits of detection. SIMS spectra were taken before heat treatment and after 24, 48, 120, 500, 1000, 1500 and 2000 hours to study the evolution of interdiffusion. Fig. 5 shows the SIMS elemental profiles in depth for Au, Ag and Ni taken on the HPCE® connector after 2000h of thermal ageing, so representative of an extreme case. This figure is a wide-range spectrum and shows the top gold layer (Au- and Au3- ions) with two intense peaks followed by, a small, very thin interdiffusion layer of (AgAu- ions) and the thick Ag layer (Ag- ions). The vertical Y axis scale was modified for the different species to better identify the Gold-Silver interface and show the interdiffusion areas. Corrosion Resistance of GCS™ plating system The pertinence of using standard corrosion tests for Ag based coating is a commonly debated subject [14,26,27] in the connector industry. Consequently, for GCS™ plating we decided to cover all aspects and to conduct Standard Bleach test (Sodium hypochlorite vapors) based on ASTM B92001(2011), Standard EIA specified Mixed Flowing 4 Gas (MFG) corrosion tests and Standard IEC high concentration SO2 (10 ppm) and H2S (1 ppm) corrosive gas exposure tests. The MFG and IEC high-SO2/H2S corrosive gas tests are performed after 100 mating/un-mating cycles. The Bleach tests are conducted on laboratory connector samples without durability cycling in order to understand the impact of lubricant and AuAg interdiffusion. Fig. 6 shows the number of pores observed on GCS™ plated terminals (12contacts) after a 105°C thermal ageing followed by the Bleach test. The results confirms that without a final lubricant layer, PAO lube in this case, we have higher porosity. This demonstrates the importance of stable and neutral lubricant usage. A direct comparison of corrosion resistance to this bleach test is made with 30GXT (0.76µm GF-PdNi) and 30Au (0.76µm Full Gold) platings for reference. We can note that GCS™ has similar corrosion resistance to GF-PdNi and Full Gold. D. 60 Number of pores (> 20µm) 2 days @ 105 C 50 5 days@ 105 C 12 days@ 105 C 40 30 20 10 0 GCS / PAO Dynamic SIMS profile of GCS plated layers on HPCE contact We can notice a very thin layer (approximately 3~6 nm) on the surface which is relatively rich in Ag, then the Ag concentration drops drastically and there is a layer (approximately 35nm to 40nm) which is extremely rich in Au. When we approach the thick Ag layer, we can notice a separate peak indicating the simultaneous presence of Au and Ag together and the thickness of such layer is estimated between 25nm and 35nm according to analyzed samples. Then, the Au diffusion into the thick Ag layer drops quickly and becomes insignificant. It can be concluded that, after this severe thermal treatment to reach the worst interdiffusion case, the Gold layer of the GCS™ plating system is performing its protective function, for silver layer, very well. This interdiffusion AuAg layer on the top surface explains that, from an aesthetic point of view, the terminals shows a color which is slightly less yellowish than the conventional aspect of Gold. Fig. 6 84 30Au ASTM Bleach porosity tests after thermal ageing. Comparison of GCS™, GXT® and Full Gold plating performances 1 30GXT GCS (PAO Lube) 0.8 0.6 0.4 0.2 0 As Plated Fig. 7 Fares Karam 30GXT The impact of MFG 4 gas tests on GCS™ electrical contact resistance are shown in Fig. 7 where tests were performed on an assembled power type connectors. GCS™ is using PAO lube and a direct comparison is made to 0.76µm GF-PdNi (30GXT) plated connectors. Contact Resistance (mΩ) Fig. 5 GCS / No Lube Durability 200x MFG : 10 days Unmated MFG : 10 days mated Standard MFG 4 gas test impact on low level contact resistance of GCS™ plated connectors 4.4 28th International Conference on Electric Contacts, 6-9 June 2016, Edinburgh Before introduction into MFG chamber, 200 durability mating and un-mating cycles were performed. The LLCR values show the stability of GCS™ plating and its high corrosion resistance. The ECR values are evidently lower for GCS than for GXT® due to the intrinsic silver electrical properties. It is important to note that 30GXT is a standard non lubricated deposit. The GCS plated (PAO lube) HPCE® connectors went through IEC high-SO2 (10ppm) and high-H2S (1ppm) corrosive gas tests after 100 mating & un-mating cycles and during 21 days for each gas. The LLCR variation results are given in Table II. We can notice that the maximal increase in ECR is very low. TABLE II. ELECTRICAL CONTACT RESISTANC VARIATION DURING GAS SULFIDATION TESTS Sulfidation Sequential Tests Description on HPCE connectors After 100 mating cycles After 21 days H2S exposure After 21 days SO2 exposure Maximum ECR Mated Connectors (mΩ) 0.04 0.01 0.02 Fig. 9 shows similar curve but for GCS™ plating which was thermally treated at 105°C (12 days) to provoke maximal AuAg interdiffusion (worst case simulation). The applied normal load was 1.2N corresponding to a contact pressure of 950 MPa, so this is representative of most of Power and Signal connectors applications. The frequency used is 10Hz and the selected stroke is ±25µm. This stroke amplitude is quite severe for electronics applications (usually we use a stroke between ±5µm and ±10µm [28,29]) but we kept evaluating under severe testing conditions. If we use 10mΩ contact resistance as the upper (maximum) threshold limit, we will notice that conventional soft silver plating alone can withstand 41K cycles before the complete wear-through of the silver layer. The fretting-corrosion curve for the GCS™ plating shows that we can reach 200K cycles. Consequently the GCS™ system is expected to have seriously improved performance in vibration tests, much better than conventional Silver plating. In summary, GCSTM plating system can withstand very harsh corrosion tests. The interdiffusion Gold-Silver layer is remains a very efficient corrosion protector for the thick silver layer. E. Fretting corrosion performance of GCSTM The lubricant enhances fretting-corrosion performance of the deposit and this is crucial for applications where connectors must withstand vibration conditions. Conventional Silver (soft silver) has moderate fretting-corrosion resistance compared to gold plating making its use very sensitive when connectors are subjected to fretting wear or to high vibration environment [28]. In general, to overcome these limitations, conventional soft silver is mainly used in high contact normal force systems with an anti-tarnish coating. In these applications, silver's relatively low hardness results in a large conducting contact area, composed of adhesively bonded metal-to-metal junctions allowing the contact to efficiently conduct current while at the same time helping to dissipate heat [14]. The GCS™ plating improves the overall durability of the contact system by using hard silver plating. Fig. 8 shows the fretting corrosion curve of a system consisting of a 1.6mm diameter full Gold plated bronze hemisphere and a flat CuSn8 bronze substrate which was plated with conventional soft Silver. Fig. 8 Fretting corrosion curve of conventioanl soft silver plating Fares Karam 85 Fig. 9 Fretting corrosion curve of GCS plating F. Current Carrying Capacity of GCSTM Given the low electrical resistivity of Silver, it is expected that the current carrying capacity would perform better with GCS™, but with AuAg interdiffisuion, it was important to carry detailed investigations. Fig. 10 shows a direct comparison between the temperature rise curves of GCS™ and GF-PdNi (GXT™) plated power connectors. We can clearly notice that GCS™, like most silver based plating, is much more adequate for higher electrical currents. It is useful to note that historically GF-PdNi temperature rise curves were very close to Full Gold plating. We did not measure, in our case, the full curve for the Gold version of the PowerBlade® connector, but simply showed (point in yellow) that when carrying 30A current, the temperature of a 0.76µm Gold plated connector is ~32% higher compared to exactly similar GCS™ plated contacts. Based on different types of tested connectors, we have noticed 15% to 20% increase in current carrying capacity in average. It is also important to compare what is the maximum temperature increase after severe environmental and corrosion tests of GCS™ connectors. Our measurements indicate that 22°C is maximum rise of temperature when contact are powered with 30A current after being submitted to thermal shocks (36 cycles, -55°C to +80 ºC) and 10 days damp heat tests (95% RH at 40°C). Even after 20 days MFG exposure, the temperature rise of GCS™ plated connectors did not bypass 19.2°C for a maximal allowed increase of 30°C. 4.4 28th International Conference on Electric Contacts, 6-9 June 2016, Edinburgh [5] [6] [7] [8] [9] [10] Fig. 10 Current carrying capacity curves of GCS™ and GXT® (GFPdNi) plated PowerBlade® connector. The yellow point represents the performance of a Full Gold plated connector [11] [12] [13] V. CONCLUSIONS The GCS™ plating system has improved performance compared to conventional silver plating systems. Even after mating/un-mating cycling, the silver layer remains protected from oxidation and sulfidation keeping its excellent electrical performance for connector usage. Connectors with GCS TM plating have a stable low coefficient of friction which makes it more adequate for connectors, requiring higher number of mating and un-mating cycles, compared to typical soft silver plating system. The GCSTM plating allows connectors to achieve high performance with lower Silver plating thickness compared to conventional Silver plating. Conventional Silver has moderate fretting-corrosion resistance compared to gold and in laboratory simulated fretting tests, however the GCS™ plating system performed almost similar to gold plating and successfully passed different vibration tests. The GCS™ plating shows a 15-20% T-Rise performance improvement compared to GXT® or Gold plating which makes it a very good plating for higher current capable power connectors. The GCS™ plating uses PAO or PFPE advanced lubricants to ensure good tribological performance without the formation of silver oxides or silver sulfide precipitation. The Gold flash layer keeps acting as an intrinsic inorganic protection for the silver layer and the lubricant is an organic self-healing protection layer. 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