Case Study: Preventing Fretting Corrosion in Electronic Control Modules
Background:
Electronic control modules (ECMs) perform various functions in automotive vehicles and protecting these components from failure has become even more important with the proliferation of electric vehicles. A leading OEM came to Nye after they noticed one of their vehicles ECMs sent an increased number of diagnostic codes related to open connections.
After further investigation they realized the connectors had experienced fretting corrosion, or minute vibrations that create oxide-build up that eventually leads to signal loss. The OEM was concerned that this would lead to braking-related safety issues including cruise control, lights, shifting out of park, etc. They approached Nye to see if we had a grease that would prevent fretting corrosion and restore connectivity to affected vehicles.
Challenge:
- Can Nye’s grease prevent fretting corrosion to eliminate oxide buildup around the connector terminals?
- Can we provide a grease that exhibits material compatibility with the plastics and elastomers used in the connector and control module housings?
Solution
NyoGel® 760G
A silica thickened, medium viscosity, synthetic hydrocarbon grease.
- Formulated to prevent fretting corrosion
- Compatible with most plastics and elastomers
- Copper passivator prevents copper corrosion
- Provides lifetime lubrication for lasting connections
- OEM Specifications: Toyota: TSK2525G-A-NY17, Ford: WSB-M1C239-A, GM: 9986087, & FCA: MS-9496
| Product | Chemistry | Temp Range (°C) | Water Washout (1hr @ 80°C) | Copper Corrosion (24 hrs @150°C) |
|---|---|---|---|---|
| NYOGEL 760G | PAO/Silica | -40 to 135 | 2% | 1a, Slight Tarnish |
Results
Nye recommended that the OEM use NyoGel® 760G, our industry standard grease for connector applications, and completed in-house validation tests for material compatibility, fretting protection, and copper corrosion protection. The OEM ultimately chose NyoGel® 760G as their connector solution because it provided the necessary fretting protection against vehicle vibration to eliminate oxide buildup around the terminals. NyoGel® 760G is now the OEMs go-to solution for recalls and to protect other control modules from failure.
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