Journal of Materials Science, Vol.52, No.13, 8231-8246, 2017
Passive films on nanocomposite carbide coatings for electrical contact applications
Nanocomposite transition metal carbide/amorphous carbon coatings (Me-C/a-C) deposited by magnetron sputtering have excellent electrical contact properties. The contact resistance can be as low as that of noble metal coatings, although it is known to vary by several orders of magnitude depending on the deposition conditions. We have investigated a nanocrystalline niobium carbide/amorphous carbon (NbC (x) /a-C:H) model system aiming to clarify factors affecting the contact resistance for this group of contact materials. For the first time, the surface chemistry is systematically studied, by angle-resolved X-ray photoelectron spectroscopy, and in extension how it can explain the contact resistance. The coatings presented a mean oxide thickness of about 1 nm, which could be grown to 8 nm by annealing. Remarkably, the contact resistances covered four orders of magnitude and were found to be exponentially dependent on the mean oxide thickness. Moreover, there is an optimum in the amount of a-C:H phase where the contact resistance drops very significantly and it is thus important to not only consider the mean oxide thickness. To explain the results, a model relying on surface chemistry and contact mechanics is presented. The lowest contact resistance of a nanocomposite matched that of a gold coating at 1 N load (vs. gold), and such performance has previously not been demonstrated for similar nanocomposite materials, highlighting their useful properties for electrical contact applications.