Wiktor Wise
When it comes to electrical connections, using the right grease is essential for both performance and safety. Electrical connectors are susceptible to atmospheric corrosion, and tin/lead connectors can also be affected by fretting corrosion caused by vibration. The right lubricant can protect against these issues, reduce mating force, and extend the life of the connector. While there are various options available, including silicone grease, dielectric grease, and fluid film, the choice depends on the specific application and environment. For instance, some greases are better suited for extreme temperatures or hazardous gases, while others are designed for domestic, automotive, or aviation use.
| Characteristics | Values |
|---|---|
| Purpose | Guarding against oxidation, fretting corrosion, contact wear, extending connector life, and reducing mating force |
| Product Type | Synthetic connector lubricants, not mineral-based |
| Product Range | Tribosyn 330, Corrosion X, Penetrox, Kernelex, Dielectric spray lube, FOTU Fully synthetic grease, Carbon Conductive Grease, and more |
| Compatibility | Some greases may cause plastics and rubbers to swell, crack, or discolour |
| Cost | Varies, with options like Tribosyn 330 being cost-effective |
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What You'll Learn
Dielectric grease
One notable product in this category is CRC Dielectric Grease Select-A-Bead, which is designed for electrical sealing, lubricating, protecting, and insulating. This grease is temperature resistant and will not harden, freeze, dry, or melt due to temperature changes. It prevents the penetration of dirt, moisture, rust, and oil, and it lubricates without adding bulk, helping to reduce wear and improve sliding action. The product's nozzle allows for easy control of the silicone bead width, and its unique double piston pressurised system ensures smooth and uniform dispensing.
When applying dielectric grease, it is important to be cautious as any excess grease between mating surfaces can disrupt the flow of electricity. It is recommended to consult an expert or refer to specific product instructions for proper application guidance. Dielectric grease is a valuable tool for protecting and maintaining electrical connections in various settings, ensuring their optimal performance and longevity.
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Silicone grease
However, despite its advantages, some sources advise against using silicone grease on electrical connectors. The main concern is that silicone can polymerise into a hard, brittle material, which can cause electrical problems and even weld connectors together. This issue is especially pertinent in low-voltage applications, such as airbag, lighting, or ABS connectors, where the voltage is relatively small and the polymerisation is more likely to cause problems.
In contrast, high-voltage applications like HT leads have a much higher voltage or force, which can break through any polymerisation of silicone. As a result, some engineers argue that silicone lubricants can be safely used on these types of connections without issue.
Ultimately, while silicone grease has its benefits, the potential for polymerisation means it may not be the best choice for all electrical connector applications. It is important to carefully consider the specific application and voltage requirements before selecting a connector grease to ensure it is suitable and safe.
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Synthetic connector lubricants
For gold-plated connectors, a suitable lubricant like NyoGel® 760G from Nye Lubricants reduces the potential for noble metal wear and damage during mating and separation. It also acts as a backup environmental seal, protecting the connector from oxygen, debris, aggressive chemicals, and other hostile elements.
Nye Lubricants offers a range of connector greases, including NyoGel® 760G, Rheotemp™ 768G, and Uniflor™ 8917, which are designed for long life and performance in high-temperature and severe environments. These greases are compatible with a wide range of connector materials and can be fortified with a UV tracer for added visibility during application and inspection.
When choosing a synthetic connector lubricant, it is important to consider the specific application and requirements. Different chemistries are utilised to meet the varied demands of the marketplace, so selecting the most suitable grease for the connector application is essential.
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Nye Lubricants
One of their most popular products is the NyoGel® 760G, a universal standard dielectric grease that has been used on connectors since the 1980s. This grease is specified by leading OEMs across multiple industries, including automotive, trucking, and power tools. NyoGel® 760G provides protection against corrosion, fretting, and power failure, and acts as a barrier against water, dust, and aggressive chemicals. It also reduces insertion force, making assembly more efficient, especially for connectors with numerous pins or in hard-to-reach places.
Other notable connector greases offered by Nye Lubricants include Rheotemp™ 768G and Uniflor™ 8917. These greases are designed for long-life and performance in severe environments, high temperatures, and high vibrations. They are compatible with a wide range of connector materials, including plastics and elastomers, and can be fortified with a UV tracer for added visibility during application and inspection.
In addition to their connector greases, Nye Lubricants also addresses misconceptions about grease affecting conductivity. They have developed an Electrical and Water Resistance test kit to demonstrate the insulative properties of their greases, proving that they do not interfere with conductivity. This kit includes NyoGel® 760G samples and the necessary equipment for engineers to conduct comprehensive tests.
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Carbon conductive grease
One of the key advantages of using carbon conductive grease is its ability to reduce contact resistance and inhibit corrosion. It is often used to improve electrical connections between irregular or pitted surfaces, such as sliding surfaces and parts, loose or vibrating parts, and battery terminals. It is also suitable for ground connections, rotating connections, rotary switches, variable capacitors, roller inductors, roller bearings, slip rings, slide connectors, and potentiometers.
When choosing an electrical connector grease, it is important to consider the specific requirements of the application. For example, some connectors may operate in extreme environments with exposure to hazardous gases or extreme temperatures, which would require a different type of grease. In addition, compatibility issues between grease and plastics or rubbers should be considered, as some oils and greases can cause swelling, cracking, or discolouration.
Overall, carbon conductive grease is a cost-effective and efficient solution for improving electrical connections and inhibiting corrosion in a variety of applications.
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Frequently asked questions
You should use electrical/electronic connector grease, which is not the same as typical 'grease'. This includes products like Tribosyn 330, Corrosion X, Penetrox, Kernelex, dielectric grease, fluid film, and silicone grease.
Lubricating electrical connectors guards against oxidation, corrosion, and contact wear, extending the life of the connector. A thin film of lubricant can also reduce mating force by up to 80%, an important factor in connector assembly.
Fretting corrosion is caused by low-amplitude vibrations from fans, motors, engines, etc., leading to micro-abrasion of contact surfaces and exposing fresh metal layers to oxidation. A lubricant film minimises metal-to-metal contact during vibration, protecting the connector.
For extreme temperatures or exposure to hazardous gases, it is recommended to consult a specialist to determine the most suitable product. Some greases may react with plastics and rubbers, causing them to swell, crack, or discolour, so care should be taken.
Carbon-based conductive greases like 846 or silver-filled 8463 are ideal for electrical connections due to their high electrical conductivity, low cost, and ease of use. Non-silicone options are also available.
