Lubricating electrical connectors has a number of benefits, including preventing oxidation, fretting corrosion, contact wear, and prolonging connector life. A thin film of lubricant can also minimize mating force by up to 80%, which is critical in connector installation. Grease is often favored over oil due to the grease’s visible ability to “remain in place” as compared to oil.
A word regarding the chemistry of the connector greases on the market….
If you’re not familiar with connection grease/lubricants, these aren’t ‘grease’ in the traditional sense if you’ve only ever used cheap grease, i.e. these aren’t mineral-based, mass-produced brown sludges. Synthetic connector lubricants are highly engineered products that come in a variety of shapes and sizes to meet the demands of real-world applications ranging from domestic to automotive, aviation, high temperature, extreme environments, and even satellite applications requiring low outgassing lubricants.
Preventing water ingress and/or preventing fretting corrosion are the two most common reasons for utilizing a connector lubricant. Are you unsure about fretting corrosion? Keep an eye out for our upcoming article, Understanding Fretting Corrosion.
A low insertion force makes assembly more efficient and provides reliable connections for complex electrical connectors with dozens or even hundreds of pins, or for automobile connectors in hard-to-reach spots. An efficient lubricant for gold-plated connectors decreases the risk of noble metal wear/damage during mating and separation.
The devices listed below are suited for electronic/electrical applications as well as digital and analogue data communications.
Lubricants protect against corrosion, oxidation, and the impacts of severe conditions. This means that gold-plated connectors will protect the substrate from corrosion. A thin film of lubricant can seal the pores, reduce substrate assault, and provide low contact resistance in thin gold plating. Manufacturers have used gold plated contacts to combat fretting corrosion over the years, but OEMs may still have to deal with fretting despite using gold because enough of the gold coating is scratched away during initial mating, negating the use of gold in the first place….especially where the gold plating thickness is probably too thin in the first place.
A special mention should be made of the capacity of a quality connection lubricant to prevent fretting corrosion in separable connectors this is obviously a critical capability of a quality connector lubricant if you are reading this because you suspect fretting concerns. In addition to air corrosion, tin/lead connectors can suffer from ‘fretting corrosion,’ which is caused by low-amplitude vibration induced by thermal expansion and contraction, as well as surrounding motion from fans, motors/engines, or anything else that vibrates the connector. Fretting corrosion promotes micro abrasion of the contact surfaces and exposes new layers of the metal surface to oxidation on a regular basis. During vibration, a lubricant film reduces metal-to-metal contact, protecting the connector from metal wear. To learn more about the facts and beliefs surrounding connector lubrication, see the accompanying information sheet Connector Grease Facts and Myths (lower down the page).
The goods listed lower down this page are suited for electronic/electrical applications as well as digital and analogue data communications. So, let’s go over the major reasons for using an electrical/electronic connector lubricant, which will most likely be one or more of the following:
To make it easier for the reader to choose, the goods are listed below in order of cost, with the Nyogel 760G being the least expensive and the Uniflor 8917 being the most expensive. Take a look at the connector lubricants that we offer…
Nyogel 760G
- The majority of consumers’ “go to” connector lubricant widely utilized and the most cost-effective option.
- The best dielectric connector grease for water and salt water resistance – this is the product on this list with the best water resistance.
- Nyogel 760G has a strong track record, particularly in the automobile industry, where it is employed by the majority of global automakers. A reliable defense against fretting corrosion, oxidation, and regular wear.
- All metals, including gold and silver, are compatible with Nyogel 760G. The most prevalent application is on tin-plated terminals.
- Because 760G has a clear/translucent look, it might be difficult to discern in thin layers; nevertheless, the recipe includes a UV tracer/dye to help visibility in small amounts.
Rheotemp 768G
- It was designed for an automotive under bonnet/under hood application where temperatures exceeded 135C, therefore 760G was not acceptable and a different chemistry was needed to achieve the requisite temperatures.
- Rheotemp 761G was originally produced under the name Rheotemp 761G, but was renamed Rheotemp 768G in 2015 after the formula was changed due to a raw material supply issue – 761G has since been discontinued.
- For gold-plated contact surfaces where water intrusion is not an issue, the 768G strikes the perfect balance of cost and performance.
- Reduces connector mating insertion forces and performs well at high temperatures.
Rheotemp 769G
- Urea thickened blend of Polyalphaolefin (PAO) and Alkylated Naphthalene (AN) base oils.
- In our lab testing, the finest performing fretting prevention dielectric connect grease.
- The product was released in 2018 and is thought to be an enhanced version of the Rheotemp 768G.
Uniflor 8917
- The best base oil lubricant for decreasing insertion forces while connecting connectors is perfluoropolyether (PFPE).
- Uniflor 8917 is perfect for large multipin connectors with strict tolerances, since it protects contact surfaces and delicate pins during assembly and mating.
- Uniflor 8917 is appropriate for hazardous settings and harsh temperatures because of its exceptional thermo-oxidative stability.
- Because the base oil employed in the composition is inert, there are little concerns with plastics or rubbers.
A word of caution concerning possible grease compatibility difficulties with plastics and rubbers. This concern applies to any use of lubricants/grease, regardless of the application or who makes the lubricant; some oils/grease can cause plastics and/or rubbers to expand, crack, or discolor. This post’s readers should not be concerned, but caution is advised, so we urge that you read our article on Lubricant and Plastic Compatibility Issues.
Take a look at our post on the “Facts and Myths of Electrical Connector Lubricants”…full it’s of interesting information! For example:
We don’t recommend using silicone-based oil on electrical contacts, as the reader may have discovered. Why? Simply said, silicones have the potential to polymerize into a hard, brittle material that might cause electrical issues. Take a look at the article Not Recommended-Silicone Lubricant Use on Electrical Connectors if you want to learn more about this topic.
What is the definition of an electrical lubricant?
Dielectric grease, often known as tune-up grease, is a non-conductive, viscous fluid intended to protect electrical connections from corrosion and grime.
Is it OK to use silicone oil on electrical connections?
Silicone oils and silicone grease are both dielectric, and silicone is generally inexpensive and abundantly available. However, any silicone-based lubricant should not be used on electrical connectors or contacts. What is the reason for this? It’s a theoretical difference between us and other companies that sell silicone-based lubricants for electrical connectors, particularly in the low-cost automobile repair market.
Silicones have properties that make them an ideal oil or (in the case of grease) base oil; they have a broad temperature range and are very inexpensive. Apart from other silicone-based materials, silicone doesn’t usually have any compatibility concerns with rubbers and plastics. Because of their low surface energy, they can migrate and cover surfaces very effectively, albeit this migratory capacity is generally seen as a disadvantage in automobile manufacturing facilities. Silicone can polymerize into a hard, brittle material that might cause electrical difficulties and weld connectors together, which is a major concern for us. Although manufacturers and sellers of silicone dielectric oil and aerosol sprays may disagree with us, the big automakers and their tier one suppliers agree. This silicone polymerisation issue only exists in electrical lubrication applications; in mechanical lubrication applications, the brittle material would be broken down by mechanical movement; in electrical applications, there is no movement other than micro-motion or fretting, which is typically associated with vibrating equipment and/or thermo-cycling. The range of movement associated with fretting behavior is unlikely to alter the polymerization of a silicone lubricant.
Are you prepared to select an electrical connector grease? Take a look at our post on Choosing Electrical Connector Grease for more information.
For silicone sprays, this is a typical HT lead application. Silicone sprays appear to be widely used on automobile High Tension (HT) leads. People frequently tell us that they have no problems using silicone lubricants on HT lead terminations. So, isn’t this evidence that we’re wrong when we claim silicone lubricants shouldn’t be used in electrical applications? The answer, like most things in engineering, is not simple, but there is a significant difference between the voltage that passes through an HT lead/spark plug connection and the voltage that passes through an airbag connector, a seat belt connector, a lighting connector, or a clock spring connector (old school reference!). Remember how electricity was compared to a river or a waterfall in school to help students grasp voltage and amperage? The amount of water flowing down a river or waterfall corresponds to the number of amps/current running through a circuit, while the voltages correspond to the force or push of that river flow/waterfall. In an HT lead application, high voltage or force/push is used to break through any polymerisation of silicone, but in a more sensitive application (for example, an airbag, lighting, or ABS connector), the voltage is much lower. HT leads can carry 5,000 or 10,000 volts, whereas a lighting connector may carry 12 or 24 volts, and more sensitive circuitry connectors in a vehicle may carry millivolts. This polymerization is a concern in lower voltage applications/connectors, but it is unlikely to be a problem in high voltage connections.
Our most affordable dielectric connector grease is made of Polyalphaolefin (PAO), which we found to be ideal for lubricating electrical connectors and contacts. If the finished grease is to be used on electrical/electronic connectors, it is obviously critical that the basic oil be accompanied by an adequate thickening. If the phrases ‘base oil’ and ‘thickener’ are unfamiliar or puzzling to you, you might want to view our video, which explains the terminologies and how a grease is made:
While a silicone-based lubricant may appear to function in the short term, their long-term performance is poor, and since our goal is long-term satisfaction, practically “lube for life,” we would not recommend a silicone spray, silicone oil, or silicone-based grease for electrical applications.
Another difficulty with silicones is silicone sprays in particular. Silicone sprays are not permitted in vehicle manufacturing plants. Of course, if the reader is not a member of an automotive manufacturing team, this information may be irrelevant, but if any painting or body work repair is planned, the reader may be interested…
Cratering and fisheyes appeared on painted surfaces a few decades ago, causing concern among vehicle makers. Light molecular weight silicone sprays used in vehicle assembly plants were discovered to be the source of the problem. When light molecular weight silicone flies through the air, it can settle in unexpected places, contaminating sheet metal. Silicone sprays are often clear, making them difficult to detect during the painting process and causing a slew of problems in the paint shop. As a result, silicones are not permitted in the manufacturing or assembly of vehicle parts.
Is it safe to use WD-40 on electrical contacts?
With proprietary Smart Straw technology, WD-40 Specialist Contact Cleaner blasts away oil, grime, flux residue, and humidity from delicate electronics and electrical equipment with precise precision. It dries rapidly, leaves little residue, and removes over 95% of common surface impurities, making it the finest choice for cleaning electrical contacts and ensuring equipment operation. Printed circuit boards, controllers, battery terminals, switches, precise instruments, and electric panels are all safe to use.
Can I use WD-40 to lubricate electrical connections?
If a socket or switch isn’t working, it needs to be disassembled and inspected. Any cables that have been detached must be reinserted and secured in the appropriate terminal. The switch must be replaced if it is damaged. Spray WD-40 Specialist Fast Drying Contact Cleaner on the terminals and electrical connectors to remove various forms of dirt and moisture on electrical or electronic equipment, including delicate materials.
How can you avoid corroding electrical connections?
Instead of utilizing non-insulated, vinyl, or nylon-insulated terminals and connections, consider employing heat shrink terminals and connectors. Moisture and impurities that cause corrosion are protected by a high-quality sealed connector. To keep moisture out, heat shrink connections are made of adhesive-lined polyolefin heat shrink tubing.
Is petroleum jelly safe to use on wire connectors?
Vaseline, often known as Petroleum Jelly, is a lubricant commonly used in industry. This is made feasible via the moistening feature. Because petroleum jelly has a low melting point, it should not be used in areas where it will be subjected to extreme heat. Petroleum jelly also has strong electrical conduction properties, making it useful in a variety of electrical applications.
Vaseline is mostly used in cosmetics, but it also has industrial applications. It’s widely utilized in the protection of metals and as a lubricant. It has special qualities that make it popular in the pharmaceutical and food preparation industries. This doesn’t mix well with any of the chemicals often used in these industries.
Is petroleum jelly effective at preventing corrosion?
Vaseline is commonly used to treat scrapes and injuries. However, this well-known brand of petroleum jelly has a variety of different applications that can help you save time and money. Robert A. Chesebrough was a scientist who grew up in New York after being born in London. He watched employees covering their cuts with residue scraped from their drills when visiting a huge oil well one day. Chesebrough conducted research on the material and discovered petroleum jelly! Vaseline was the name he gave to his invention, which he patented in 1872.
He’d then go from town to town, demonstrating his amazing innovation. He would harm himself in front of big crowds and apply Vaseline to his wounds. His listeners would be terrified as he burned his arms and legs over open fires. Chesebrough lived to be 98 years old, and he said that a spoonful of Vaseline every day kept him alive.
Vaseline is now used for a variety of purposes, including pet care, painting, corrosion prevention, igniting fires, and more. Check out these petroleum jelly applications to keep prepared for any emergency.
Do you want to paint your door but don’t want splatters on the hinges or frame? Simply apply petroleum jelly to the places you’d like to keep paint away from. Paint away, then wipe away the petroleum jelly after the paint has dried.
Don’t you despise it when you can’t open the glue container because it’s effectively sealed shut? Apply a dab of petroleum jelly to the inside of the glue bottle lid the next time you open it, and it will be much easier to undo!
Petroleum jelly works well as a sealant as well. If you’re worried that your plunger in the bathroom isn’t working and you need a better seal, try Vaseline! You’ll be able to create a better seal and suction if you cover the plunger’s rim with jelly.
Simply apply a little petroleum jelly over each eye to keep flies out of your horse’s eyes. Flies should be kept at bay as a result of this.
Hopefully, your automobile battery isn’t so corroded that the rods are unable to connect properly. However, if you want to preserve your car batteries from corroding, treat the rods with petroleum jelly every now and then to keep them from corroding. A copper penny can also be taped to the top of the pole. The corrosion will be drawn to the penny rather than the battery posts.
Petroleum jelly is effective at preventing rust on tools and other metal objects in addition to preventing corrosion. After cleaning your instruments, lightly treat them with Vaseline and you’re ready to go. Wipe some petroleum jelly on instruments that you only use once in a while and wrap them in a cloth to keep them for a longer time.
Vaseline is an excellent fire starter, in addition to its protecting capabilities. In your 72-hour kit, place a dozen cotton balls saturated in petroleum jelly in a plastic bag. Place the cotton balls around the base of the fire if you’re having problems lighting it. When you light the cotton balls, they will assist you in maintaining a roaring fire.
Leave a comment below to tell us about your experiences. Check out what other people have done with petroleum jelly and how you can utilize it in an emergency. Check out our complete list of emergency supplies essentials to round out your emergency pack.