Recent advances in silver-matrix composite electrical contact materials: microstructural design, properties enhancement, and rare-earth modification

As core functional materials for electronic devices, silver-matrix composite electrical contact materials (Ag-MC-ECMs) directly determine the safety and operational reliability of associated electrical systems. A long-standing bottleneck for conventional Ag-MC-ECMs is the unavoidable trade-off between high electrical conductivity and robust arc erosion resistance under extreme service conditions. This review examines recent advances in the processing, microstructural regulation, performance mechanisms, and rare-earth (RE) functionalization of Ag-MC-ECMs. Processing routes are systematically compared across four key metrics: reinforcing phase dispersion, densification efficiency, interfacial bonding, and structural controllability. Cross-scale analysis is conducted to elucidate the effects of interfacial electronic structure, reinforcing phase topology, and wettability on arc-erosion performance. Special focus is placed on three-dimensional (3D) reinforcing networks and RE functionalization, which act as complementary structural and chemical strategies for mitigating performance trade-offs. The core contributions of this review are threefold. First, it establishes a unified multiscale framework that correlates reinforcing phase dispersion, processing-induced densification, interfacial structure, 3D phase topology, and RE chemistry to the holistic electrical contact performance of Ag-MC-ECMs. Second, it constructs a cross-scale mechanistic model linking interfacial electronic structure, charge transport behavior, molten pool evolution dynamics, contact material transfer, and ultimate arc erosion resistance. Third, it develops a coordination chemistry–based interpretation of RE oxidation behavior, and proposes an integrated design roadmap combining topological optimization, additive manufacturing, standardized experimental protocols, and machine learning–assisted inverse design.