The way that you guarrantee contact reliability is by forcing current to flow, every time the contact points are moved. This causes microscopic welds.

Relays for aircraft use have a specification for minimum current, for this purpose.


Karel Kulhavy wrote:

Hello

What are the conditions under which 100% reliable contact between two metals
is guaranteed? My hypothesis is that there are only two possibilities:

1) gold-to-gold
2) The touch point is under permanent great preload which causes the crystal
lattices to deform plastically and be fused together (like in wire nuts -
you can see the denting on the wire)

The contact is supposed to be generally subject to high-amplitude thermal
cycles (-30 to +70 degC) for years with very difficult maintenance. It
won't be subject to condensing humidity or direct weather exposure. And
must be repeatedly disassemblable without soldering.

Cl<




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