Signaling Relay Contact Failure Analysis with 3D Profilometry, SEM and EDS

International Journal of Mechanical Engineering

© 2024 by SSRG - IJME Journal

Volume 11 Issue 1

Year of Publication : 2024

Authors : Susmita Sau, Sajjan Kumar, Sankar Narayan Patra, Subhash Chandra Panja

10.14445/23488360/IJME-V11I1P103

How to Cite?

Susmita Sau, Sajjan Kumar, Sankar Narayan Patra, Subhash Chandra Panja, "Signaling Relay Contact Failure Analysis with 3D Profilometry, SEM and EDS," SSRG International Journal of Mechanical Engineering, vol. 11,  no. 1, pp. 28-38, 2024. Crossref, https://doi.org/10.14445/23488360/IJME-V11I1P103

Abstract:

Electromagnetic relays may fail after long-term usage, which is a regular incident. Electromagnetic relay plays a vital role in the interlocking of railway signalling systems. To run the train in fail-safe conditions, signalling components have to work correctly. The signalling relay is an empirical part of the signalling system. Silver-Impregnated Graphite (SIG) contacts are commonly used in the metal to carbon contact relay. Contact resistance becomes high. Disintegration of the contact surface occurs due to erosive wear. A thin film of sulphide and oxide is formed on it due to environmental stress, such as moistness, weather, oxidizing agents, etc. This paper deals with the contact failure analysis of both QN1 series relay contacts. Surface roughness analysis was done through 3D profilometry for both used and unused contacts. Roughness parameters have been calculated. SEM, EDS, and FESEM investigate silver-permeated graphite contact. Surface analysis of SIG contact involves employing SEM to examine the film deposition process, enabling thorough examination of surface attributes. The molecular components of this micro-coating have been investigated by using energy EDS for both SIG contact and silver contact. Oxide, carbide, and sulphide thin coating were identified. High-resolution images of the surface captured by FESEM and SEM feature roughness and a porous structure due to oxidation, sulphation, and corrosion of the contact surface. The investigation of relay contacts prior to thin layer development and successive to high contact resistance indicates that the persistent operation of QN1 series relays culminates in mechanical weakening and transformation, ultimately leading to relay malfunction.

Keywords:

Signalling relay, Failure analysis, Roughness analysis, Scanning Electron Microscopy, Energy dispersive X-Ray spectroscopy, Field Emission Scanning Electron Microscopy.

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