Degradation of road tested automotive connectors

The automotive environment is particularly demanding on connector performan ce, and is characterized by large temperature changes, high humidity and co rrosive atmospheres. This paper presents an initial study of connector perf ormance in terms of temperature profiles taken from road vehicles. The temp erature profiles are then simulated using empirical relationships to allow prediction of connector performance. Wire harnesses have been investigated to seek evidence of the connector deg radation predicted from the temperature data. Initial indications are that the wire harness shows the type of fretting behavior associated with the te mperature changes. Evidence of fretting corrosion aas found at the contact interface on tin plated terminals from sealed and unsealed connectors.