To address the electrical wear and contact welding issues during the closing operation of high-power DC contactors

this study designs a Cu-W composite contact with an ordered rhombic dodecahedron skeleton featuring three-dimensional interpenetrating structure. Through coupled multiphysics simulations (thermal-fluid-mechanical) and experimental validation

the study systematically investigates how this structure influences molten pool morphology

droplet splattering behavior

and mass loss. Simulation results demonstrate that compared to conventional disordered structures

the ordered rhombic dodecahedron skeleton reduces contact surface temperature by 11.9% and decreases molten pool area by 46.1%. Experimental data confirm that this structure suppresses bouncing arc energy by 56.1%

reduces welding force by 40.3%

and decreases mass loss by 51% relative to disordered contacts. The underlying mechanism lies in the ordered skeleton's effective dissipation of arc energy accumulation through directional heat conduction

while the 3D interpenetrating network geometrically confines molten metal flow

significantly inhibiting splattering loss. This research provides a novel structural optimization strategy for designing highly reliable electrical contact materials.