A method for selecting metal alloys as the electric contact materials for
microelectromechanical systems (MEMS) metal contact switches. This method
includes a review of alloy experience, consideration of equilibrium
binary alloy phase diagrams, obtaining thin film material properties and,
based on a suitable model, predicting contact electrical resistance
performance. After determination of a candidate alloy material, MEMS
switches are conceptualized, fabricated and tested to validate the alloy
selection methodology. Minimum average contact resistance values of 1.17
and 1.87 ohms are achieved for micro-switches with gold (Au) and
gold-platinum (Au-(6.3 at %)Pt) alloy contacts. In addition,
`hot-switched` life cycle test results of 1.02.times.10.sup.8 and
2.70.times.10.sup.8 cycles may be realized for micro-switches with Au and
Au-(6.3 at %)Pt contacts. These results indicate increased wear with a
small increase in contact resistance for MEMS switches with metal alloy
electric contacts.