MIL-L-87177 Lubricant Bulletproofs Connectors Against Chemical and Fretting Corrosion
Electrical connectors corrode. Even our best SA and MC connectors finished with 50 to 100 microinches of gold over 50 to 100 microinches of nickel corrode. This work started because some, but not all, lots of connectors held in KC stores for a decade had been destroyed by pore corrosion (chemical corrosion). We have identified a MIL-L-87177 lubricant that absolutely stops chemical corrosion on SA connectors, even in the most severe environments. For commercial connectors which typically have thinner plating thicknesses, not only does the lubricant significantly retard effects of chemical corrosion, but also it greatly prolongs the fretting life. This report highlights the initial development history and use of the lubricant at Bell Labs and AT&T, and the Battelle studies and the USAF experience that lead to its deployment to stop dangerous connector corrosion on the F-16. We report the Sandia, HFM&T and Battelle development work, connector qualification, and material compatibility studies that demonstrate its usefulness and safety on JTA and WR systems. We will be applying MIL-L-87177 Connector Lubricant to all new connectors that go into KC stores. We recommend that it be applied to connectors on newly built cables and equipment as well as material that recycles through manufacturing locations from the field.