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<p>The electrical lifetime of contacts has long been a critical issue in the study of electrical contact materials, with dynamic welding identified as a dominant failure mechanism. Traditional investigations into the welding process have primarily focused on thermal source modeling, often neglecting the direct influence of arc behavior on molten pool evolution. To elucidate the regulation mechanism of microstructural features in arc-induced welding, this study investigates Cu-W composite contacts with ordered quadrilateral and rhombic dodecahedron architectures. A coupled thermo-electro-fluid numerical model is developed by introducing arc heat sources and external magnetic fields to simulate the dynamic welding process. Key parameters such as temperature distribution, current density distribution, molten pool morphology, and welding force evolution are systematically analyzed. The results demonstrate that ordered Cu-W skeletal structures exhibit superior anti-welding performance, significantly enhancing both the welding resistance and operational stability of the contacts. Compared with disordered contacts, the welding force of the quadrilateral and rhombic dodecahedral contacts is reduced by 28.52% and 34.15%, respectively. This study provides a theoretical foundation and technical reference for microstructural optimization of contact materials to improve their arc erosion resistance and extend their service life<b>.</b></p>

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Study on Arc-Induced Welding of Cu-W 3D Interpenetrating Electrical Contacts Based on Thermo-Electro-Fluid Multiphysics Coupling

  • 期刊论文

  • 发表日期：

    2026年1月23日

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  • Ying Han,
  • Lipeng Zhang,
  • Jiangshan Wang,
  • Shixin Su,
  • Xiaoling Ning,
  • Kun Li

摘要

The electrical lifetime of contacts has long been a critical issue in the study of electrical contact materials, with dynamic welding identified as a dominant failure mechanism. Traditional investigations into the welding process have primarily focused on thermal source modeling, often neglecting the direct influence of arc behavior on molten pool evolution. To elucidate the regulation mechanism of microstructural features in arc-induced welding, this study investigates Cu-W composite contacts with ordered quadrilateral and rhombic dodecahedron architectures. A coupled thermo-electro-fluid numerical model is developed by introducing arc heat sources and external magnetic fields to simulate the dynamic welding process. Key parameters such as temperature distribution, current density distribution, molten pool morphology, and welding force evolution are systematically analyzed. The results demonstrate that ordered Cu-W skeletal structures exhibit superior anti-welding performance, significantly enhancing both the welding resistance and operational stability of the contacts. Compared with disordered contacts, the welding force of the quadrilateral and rhombic dodecahedral contacts is reduced by 28.52% and 34.15%, respectively. This study provides a theoretical foundation and technical reference for microstructural optimization of contact materials to improve their arc erosion resistance and extend their service life.