Sliding electrical contact properties of highly oriented copper fiber brush

Abstract

Metal fiber brush is a new electrical brush that has a promising application in high current density and non-lubricating conditions owing to its unique structure. The copper fiber brush comprised of highly oriented and uniformly distributed fibers was prepared by the knitting method with a packing fraction of 20%. The influence of current on the sliding electrical contact properties of the copper fiber brush as sliding against the steel disc was investigated. The worn surfaces of the copper fiber brushes and the steel discs were characterized to reveal the involved wear mechanisms. The results show that the static contact resistance decreases significantly from 55 to 18 mΩ with the gradual increase of contact force from 1 to 8 N, which is attributed to the elastic contact of multiple fibers and good compressive performance. The sliding contact resistance and electrical noise decrease with the increase of current, which is attributed to the micro-welding of contact spots induced by an electric arc. The wear rate of copper fiber brush increases significantly from 1.2 × 10−5 to 5.7 × 10−5 mm3/N·m with the increase of current from 0 to 8 A. The electrical wear caused by arc erosion becomes the dominant wear mechanism, which is more profound than mechanical wear under high currents.