In modern electrical systems, relays play a crucial role in controlling circuits, switching between open and closed states to manage electrical loads. However, one of the most common and potentially destructive issues that arise in high-power relay systems is contact welding. Contact welding occurs when the electrical contacts inside the relay fuse together due to excessive heat, creating a permanent or semi-permanent connection between the contacts. This failure can result in circuit malfunction, equipment damage, and even fire hazards. To address this, the Power Relay Contact Welding Solution focuses on methods and technologies to prevent contact welding and ensure reliable and safe operation of power relays in demanding applications.
What Is Contact Welding? Contact welding is a phenomenon that occurs when electrical contacts in a relay, under high-current or high-voltage conditions, generate excessive heat due to resistance or arcing. Over time, this heat can cause the metal surfaces to melt and fuse together, effectively “welding” the contacts in the closed position. Once welded, the relay can no longer open or close properly, rendering the relay and, in some cases, the entire system inoperable. The primary causes of contact welding include： High Inrush Currents： When relays switch large currents, particularly in inductive or capacitive loads, an initial surge of current may occur, exceeding the relay’s contact capacity.