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Failure analysis of corroded 500 kV connectors made of silver plated ASTM 356 aluminum alloy

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? 2022 Elsevier LtdThis work reports investigation of the premature corrosion of power connectors made of silver plated ASTM 356 cast aluminum alloy from a Brazilian substation. Both the 500 kV and neutral terminals underwent severe oxidation and plating delamination, causing their electrical failure. The corrosion mechanism and failure root cause were investigated through visual inspection, optical microscopy, scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction. The analysis revealed several defects in the plating, which exposed both the aluminum substrate and silver coating to electrolytes (humidity/rainwater), forming a galvanic couple. Moreover, the preferential dissolution of the aluminum rich areas, due to micro-galvanic corrosion, resulted in loss of loose aluminum particles that left the plating without mechanical support. Therefore, the electrical failure of the connectors occurred due to the existence of defects in the plating, causing severe galvanic corrosion of the substrate, aggravated by the micro-galvanic corrosion of the aluminum rich regions.

Electrical connectorsGalvanic corrosionMicro-galvanic corrosionPlatingSurfaces and interfaces

Luiz L.A.、Gobi C.M.、de Andrade J.、Peres E.、Paro O.

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Mechanical Engineering Department Federal University of Paraná

Materials Department LACTEC Institute

XRTE - Xingu Rio Transmissora de Energia S.A

2022

Engineering failure analysis

Engineering failure analysis

EISCI
ISSN:1350-6307
年,卷(期):2022.136
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