Protecting Electric Contacts: Preventing Corrosion For Longevity

Corrosion of electrical contacts is a common issue, especially in environments with high humidity or exposure to water, salt, and chemicals. To protect electrical contacts from corrosion, it is crucial to understand the underlying causes and take preventive measures. Corrosion can be caused by various factors, including water, sweat, old leaking batteries, and electrolytic processes. Preventing corrosion involves keeping electrical contacts dry, using dielectric grease or conformal coatings, and regularly inspecting and cleaning connections. Additionally, specific products like Nyalic anti-rust protection and Boeshield T9 are designed to protect electrical components from corrosion.

Characteristics and Values of Protecting Electric Contacts from Corrosion

Keep moisture out

As water is typically the culprit behind electrical corrosion, keeping moisture away from electrical contacts should be a top priority. To achieve this, regularly inspect your electrical panel and connections for any signs of water intrusion, such as leaks or cracks in indoor walls and foundations, and ensure that outdoor wiring is not exposed to garden or rainwater.

One effective way to keep electrical contacts dry is to use dielectric grease, which seals and prevents moisture accumulation around wiring. You can also use a conformal coating or a dielectric grease like Nyalic, an anti-rust and corrosion-resistant coating that can be applied to electrical connectors, PC boards, and battery terminals. Additionally, consider using a contact cleaner, a precision aerosol spray that dissolves and removes dirt, oil, and oxidation from electrical components.

For those seeking a more accessible option, WD-40 is a mild solvent that is safe to use on electrical contacts. It helps remove corrosion and protects metals from future corrosion by leaving a slight residue. Another simple solution is to use vinegar, which can be applied with a Q-tip and then cleaned off with a toothbrush.

It is worth noting that some people have recommended keeping connections disconnected and only powering them when in use. This method can be effective in preventing corrosion, but it may not be practical for all situations.

Use dielectric grease

Dielectric grease is a viscous, non-conductive, waterproof substance used to protect electrical connections from corrosion and dirt. It is made from a silicone base and a thickener, and it repels moisture and protects electrical components from corrosion. It is most commonly used on automobiles but has a wide range of applications, from traffic lights to marine uses.

Dielectric grease can be applied to the metal parts of any electrical connection that will be exposed to the elements. It acts as a sealant, lubricant, insulator, and protectant. It is important to note that application should be done carefully, as the grease will cut off the electricity flow if it is left between the mating surfaces. When used with batteries, it is recommended to attach the cable to the terminal first and then apply the grease on top. This is because if the grease is applied to the terminal first and then the cable, there is a risk of insulation between the two.

Dielectric grease is particularly useful for those with boats, as it can be applied to battery terminals, spark plugs, electrical contacts, shore power inlets, and boat electronics connectors. It is also useful for trailer plugs, light bulbs, and fish finders. The grease maintains electrical performance in various conditions, including rain, fog, salt spray, and temperature extremes.

Overall, dielectric grease is an effective way to protect electrical contacts from corrosion by repelling moisture and sealing electrical connections.

Use contact cleaner

Using a contact cleaner is an effective way to protect electric contacts from corrosion. Electrical contacts can get dirty or corroded with normal use, which affects their performance. Corrosion can be caused by moisture, age, and oxidation. Therefore, it is important to keep electrical contacts clean and free from dirt, dust, and debris.

Contact cleaners, also known as electrical cleaners, switch cleaners, or battery terminal cleaners, are designed to remove contamination from electrical contacts. They are usually solvent-based cleaners that come in pressurized aerosol packaging. These cleaners are formulated to quickly and effectively remove dirt, oil, and oxidation build-up from electrical components and contacts.

When using a contact cleaner, it is important to follow certain precautions. Firstly, always disconnect the power source before cleaning to avoid electrical shock. Wear gloves and eye protection to safeguard against any chemicals and solvents used in the cleaning process. It is also recommended to work in a well-ventilated area to avoid inhaling any fumes from the cleaner.

To clean the electrical contacts, apply gentle pressure to avoid damaging them. Use a cotton swab, soft-bristled brush, or a lint-free cloth to wipe away any dirt, grime, or corrosion. Ensure that you remove any excess cleaner or debris from the contacts after cleaning. Allow the contacts to dry completely before reconnecting the power source to prevent any moisture buildup, which can lead to corrosion.

Some recommended contact cleaners include the Techspray E-LINE Contact Cleaner, which is a powerful mix of hydrocarbon and alcohol solvents. Another option is the G3 Contact Cleaner, which offers the added benefit of being non-flammable while still providing excellent cleaning performance. Commercial electrical contact cleaners such as those by CRC and WD-40 are also effective in removing corrosion.

Use conformal coating

Conformal coating is a special polymeric film-forming product that protects circuit boards, components, and other electronic devices from adverse environmental conditions. These coatings are designed to 'conform' to the inherent irregularities in the structure and environment of the PCB. Conformal coatings provide increased dielectric resistance, operational integrity, and protection from corrosive atmospheres, humidity, heat, fungus, and airborne contamination such as dirt and dust.

There are several types of conformal coatings available, each with its own unique properties and applications. Acrylic conformal coating, for example, provides fair elasticity and general protection. It is known for its high dielectric strength and fair moisture and abrasion resistance. Acrylic coatings are also easily removed by solvents, making them practical and economical for reworks and repairs. However, they do not protect against solvents and solvent vapors, which may result in less than ideal performance for certain applications.

Parylene conformal coating is another option that provides excellent dielectric strength and superior resistance to moisture, solvents, and extreme temperatures. Due to the vapor deposition method, parylene coatings can be applied thinly while still offering excellent circuit board protection. However, removal for rework is challenging and requires specialized equipment for recoating.

When applying conformal coating, it is important to consider the application method and ease of rework. While conformal coating provides excellent protection, it can affect overall cooling and make it difficult to swap components. Therefore, it is crucial to assess the specific requirements and constraints of your electronics before selecting the most suitable conformal coating.

Overall, conformal coating is an effective solution to protect electric contacts from corrosion and ensure the longevity and optimal performance of electronic devices.

Keep connections disconnected

Keeping electrical connections disconnected is a simple yet effective way to prevent corrosion. This method is especially useful for connections in corrosive environments, such as those near the coast or in industrial settings, where salt, water vapour, and other contaminants are present.

By keeping connections disconnected, you eliminate the possibility of corrosion caused by electrical currents. This is because certain types of corrosion, such as copper salt formation, occur only in the presence of moisture and a direct current. Disconnecting the power source prevents this type of corrosion from occurring.

Additionally, regular inspections of wiring and electrical panels are crucial. Before issues arise, check that nothing is deteriorating, rusting, or oxidizing. Pay close attention to outdoor lighting and areas exposed to the elements, as they are at higher risk of corrosion.

To further protect disconnected connections, you can apply dielectric grease or silicone grease. These substances create a barrier that seals out moisture and prevents corrosion. However, it's important to note that grease might not be a suitable solution for all situations, especially in environments where grease is undesirable, such as boats.

Another option for disconnected connections is to use a conformal coating or an anti-rust protection product like Nyalic. These coatings provide an extra layer of protection against corrosive elements and moisture, reducing electrical failures caused by corrosion.

Frequently asked questions