Keeping this vast network running reliably depends not only on millions of base stations, but also, in part, on the
electrical contacts inside the power distribution, protection, and control equipment that supports them.
According to China's Ministry of Industry and Information Technology, China had deployed 5.102 million 5G base stations by the end of June 2026, accounting for more than 60% of the global total. Under China's 15th Five-Year Plan (2026–2030), China plans to build 500,000 5G-Advanced (5G-A) base stations. Over the same period, the broader development of next-generation communications networks is projected to generate approximately RMB 7 trillion in economic output across related industries.
As base station deployment continues, computing infrastructure expands, and end devices evolve, demand for reliable communications equipment and components is expected to grow. At the same time,
5G infrastructure is moving toward higher power density and more compact, integrated designs, creating tougher operating conditions for electrical switching and connection points.
In relays, DC circuit breakers, and other power-control devices used in communications systems, contact material selection influences electrical performance, switching reliability, temperature rise, and service life. High-performance, reliable contact materials therefore play an important role in supporting the long-term stability of 5G infrastructure.
Contact Material Challenges in 5G Infrastructure
The evolution of 5G infrastructure is reshaping the operating requirements for electrical contacts. As equipment becomes more compact and power-dense, the limitations of conventional contact materials can become more pronounced, creating new challenges for long-term equipment reliability.
1. Higher Current Density in Compact Designs
As power distribution and control modules in 5G base stations become smaller and more integrated, less space is available for switching components, even as current-carrying requirements increase in many applications. The resulting rise in current density can lead to excessive contact temperature rise.
Higher temperatures can increase contact resistance and accelerate surface oxidation, creating a reinforcing cycle of heat buildup and electrical degradation. In protection devices, excessive heat may also contribute to nuisance tripping and disrupt normal equipment operation.
2. Arc Erosion and Contact Welding Under Demanding Switching Conditions
Switching mechanical contacts under load can generate an electric arc. Over time, repeated arcing can erode contact surfaces, cause material transfer, and increase the risk of contact welding.
Contact welding is one of the most serious failure modes. If the force holding the contacts together exceeds the switching mechanism's separation force, the contacts may fail to open, compromising the device's switching or circuit protection function. Applications involving repeated switching, high inrush currents, fault interruption, or DC loads therefore place particularly demanding requirements on contact materials.
3. Exposure to Demanding Outdoor Environments
Many 5G base stations and related facilities operate in outdoor or semi-protected environments. Temperature cycling, high humidity, salt mist in coastal regions, and airborne contaminants can promote oxidation and corrosion, destabilize contact resistance, and accelerate material degradation.
Without appropriate material selection and protective design, these conditions can reduce switching reliability and shorten component service life.
Conventional contact materials may struggle to meet this combination of electrical, thermal, mechanical, and environmental requirements. Material solutions for 5G infrastructure must balance high conductivity and low, stable contact resistance with resistance to arc erosion, contact welding, and environmental degradation. They must also be matched to the actual voltage, current, load type, switching frequency, operating environment, and required service life of each application.
Fudar Alloy’s Contact Material Solutions for 5G Infrastructure
To address the electrical, thermal, and environmental challenges found in 5G infrastructure,
Fudar Alloy develops application-specific contact material solutions through material formulation, manufacturing process optimization, and product design. Our portfolio supports relays, DC circuit breakers, and other switching and protection devices used in communications equipment.
Relays for 5G Base Station Modules: AgSnO₂/Cu Contact Rivet Solution
For relays used in 5G base station modules, one customer required the voltage drop across the contacts to remain below 55 mV under specified electrical endurance test conditions. With the conventional contact material, the voltage drop increased during the later stages of testing and eventually exceeded the specified limit. This contributed to excessive temperature rise and reduced the long-term operational stability of the equipment.
Fudar Alloy developed a tailored AgSnO₂/Cu
contact rivet solution for this application. AgSnO₂ offers strong resistance to arc erosion and material transfer, making it well suited to demanding switching conditions. The composite rivet design combines an AgSnO₂ working layer with a copper base. By optimizing the material proportions and interfacial bonding process, the solution achieved a better balance of temperature-rise performance, electrical endurance, and bonding integrity.
Customer testing showed that the contact voltage drop remained within the specified limit throughout the endurance test. By limiting voltage-drop drift, the solution improved long-term contact stability and helped reduce failure risk, extend equipment service life, and lower maintenance requirements.
DC Circuit Breakers: AgSnO₂ Contact Tips with a BAg15CuP Brazing Layer
For DC circuit breakers used in 5G power distribution systems, one customer's existing contact solution exhibited excessive temperature rise, insufficient resistance to contact welding, and limited electrical endurance. These issues could compromise operating reliability and increase maintenance requirements.
Fudar Alloy developed an AgSnO₂
contact tip solution with a BAg15CuP brazing layer. An atomized powder process was used to achieve tighter control of the material microstructure and a more uniform dispersion of SnO₂ particles within the silver matrix. This uniform microstructure supports consistent resistance to arc erosion and contact welding under high-current switching conditions.
The BAg15CuP layer provides a reliable brazing interface between the contact tip and its copper carrier, helping the joint withstand the thermal and mechanical stresses generated during operation.
Customer validation showed that the assembled circuit breaker achieved 8,000 electrical operating cycles, compared with 3,000 previously. Its mechanical endurance also reached 20,000 cycles, up from 12,000. By extending electrical service life and improving operating stability, the solution helped reduce lifecycle maintenance requirements and increase the equipment's safety margin.
Supporting the Next Generation of Communications Infrastructure
Reliable communications infrastructure depends on numerous components working together—including the electrical contacts that help maintain safe and stable power distribution.
With decades of experience in electrical contact materials, Fudar Alloy combines material formulation expertise, advanced manufacturing processes, and application-specific product design to address the evolving requirements of 5G infrastructure.
Looking ahead, we will continue to follow advances in communications technology and develop higher-performance electrical contact materials that support reliable power control and protection in 5G and next-generation communications networks.
