Synergistic regulation of current-carrying wear performance of resin matrix carbon brush composites with tungsten copper composite powder

Resin matrix carbon brush composites (RMCBCs) are critical materials for high-powered electric tools. However, effectively improving their wear resistance and heat dissipation remains a challenge. RMCBCs prepared with flake graphite powders that were evenly loaded with tungsten copper composite powder (RMCBCs-W@Cu) exhibited a low wear rate of 1.63 mm3/h, exhibiting 48.6% reduction in the wear rate relative to RCMBCs without additives (RMCBCs-0). In addition, RMCBCs-W@Cu achieved a low friction coefficient of 0.243 and low electric spark grade. These findings indicate that tungsten copper composite powders provide particle reinforcement and generate a gradation effect for the epoxy resin (i.e., connecting phase) in RMCBCs, which weakens the wear of RMCBCs caused by fatigue under a cyclic current-carrying wear.