Tribological and electric-arc behaviors of carbon/copper pair during sliding friction process with electric current applied

The tribological behaviors of carbon block sliding against copper ring with and without electric current applied were investigated by using an advanced multifunctional friction and wear tester, and the electric-arc behaviors were analyzed in detail. The results show that the normal load is one of the main controlling factors for generation of electric arc during friction process with electric current applied. The strength of electric arc is enhanced with the decrease of normal loads and the increase of electric currents. The unstable friction process and the fluctuated dynamic friction coefficients are strongly dependent upon the electric arc. The wear volumes and the wear mechanism of carbon brush were affected by the electric arc obviously. As no electric arc occurs, no clear discrepancy of the wear volumes of the carbon samples with and without electric current applied could be detected. While the wear mechanisms are mainly mechanical wear. However, under the condition of the electric arc appearance, the wear volume of carbon with electric current applied increases much more rapidly than that without electric current applied and also increases obviously with the increase of electric current strengths and the decrease of normal loads. The wear mechanisms of carbon block are mainly electric arc ablation accompanying with adhesive wear and material transferring.

Tribological behavior and wear mechanism of resin-matrix contact strip against copper with electrical current

The resin-matrix pantograph contact strip (RMPCS),which has excellent abrasion resistance with electrical current and friction-reducing function,was developed in view of the traditional contact strips with high maintenance cost,high wear rate with electrical current and severe damage to the copper conducting wire.The characteristics of worn surfaces,cross-section and typical elemental distributions of RMPCS were studied by scanning electron microscopy (SEM) and energy dispersion spectrometry (EDS).The wear behavior and arc discharge of RMPCS against copper were investigated with self-made electrical wear tester.The results show that the electrical current plays a critical role in determining the wear behavior,and the wear rate of the RMPCS against copper with electrical current is 2.7-5.8 times higher than the value without electrical current.The wear rate of the contact strip increases with the increase of the sliding speed and electrical current density.The main wear mechanism of RMPCS against copper without electrical current is low stress grain abrasive and slightly adhesive wear,while arc erosion wear and oxidation wear are the dominate mechanism with electrical current,which is accompanied by adhesive wear during the process of wear.

Morphology and Frictional Characteristics Under Electrical Currents of Al_2O_3/Cu Composites Prepared by Internal Oxidation

Two Al2O3/Cu composites containing 0.24 wt.% Al2O3 and 0.60 wt.% Al2O3 separately are prepared by internal oxidation. Effects of sliding speed and pressure on the frictional characteristics of the composites and copper against brass are investigated and compared. The changes in morphology of the sliding surface and subsurface are examined with scanning electron microscope （SEM） and energy dispersive X-ray spectrum （EDS）. The results show that the wear resistance of the Al2O3/Cu composites is superior to that of copper under the same conditions, Under a given electrical current, the wear rate of Al2O3/Cu composites decreases as the Al2O3-content increases, However, the wear rates of the Al2O3/Cu composites and copper increase as the sliding speed and pressure increase under dry sliding condition. The main wear mechanisms for Al2O3/Cu composites are of abrasion and adhesion; for copper, it is adhesion, although wear by oxidation and electrical erosion can also be observed as the speed and pressure rise.

Tribological behavior of CNTs-Cu and graphite-Cu composites with electric current

CNTs-Cu and graphite-Cu composites were separately prepared by powder metallurgy technique under the same consolidation processing. Tribological behavior of the composites with electric current was investigated by using a pin-on-disk friction and wear tester. The results show that the friction coefficient and wear rate of the composites decrease with increasing the reinforcement content, and increase with increasing the electric current density; the effects of electric current are more obvious on tribological properties of graphite-Cu composites than on CNTs-Cu composites; for graphite-Cu composites the dominant wear mechanisms are electric arc erosion and adhesive wear, while for CNTs-Cu composites are adhesive wear.

Friction and wear behaviors of TiCN coating based on electrical discharge coating

Titanium carbonitride (TiCN) coating was prepared on 45# carbon steel by electrical discharge coating (EDC), and the compositions, morphology and microstructure of the coating were studied. In addition, its friction and wear behaviors relative to the physical vapor deposition (PVD) TiN coating were investigated. The results show that the TiCN coating features a thickness of 15μm with a primary phase of TiC 0.3 N 0.7 . The wear rates of the two coatings have no clear distinction at low applied loads. However, severe abrasive wear appears in the PVD TiN coating when the applied load exceeds 30 N, while the TiCN coating features better wear resistance. The abrasive wear with coating peelings is found to be the predominant wear mechanism at high applied loads.

Effect of Electrical Current on the Tribological Behavior of the Cu-WS_2-G Composites in Air and Vacuum

As the traditional graphite-based composites cannot meet the requirement of rapid developing modern industry, novel sliding electrical contact materials with high self-lubricating performance in multiple environments are eagerly required. Herein a copper-based composite with WS2 and graphite as solid lubricant are fabricated by powder metallurgy hot-pressed method. The friction and wear behaviors of the composites with and without current are investigated under the condition with sliding velocity of 10 m/s and normal load of 2.5N/cm 2 in both air and vacuum. Morphologies of the worn surfaces are observed by optical microscope and compositions of the lubricating films are analyzed by XPS. Surface profile curves and roughness of the worn surfaces are obtained by 2205 surface profiler. The results of wear tests show that the friction coefficient and wear volume loss of the composites with current are greater than that without current in both air and vacuum due to the adverse effects of electrical current which damaged the lubricating film partially and roughed the worn surfaces. XPS results demonstrate that the lubricating film formed in air is composed of oxides of Cu, WS2 , elemental S and graphite, while the lubricating film formed in vacuum is composed of Cu, WS2 and graphite. Because of the synergetic lubricating action of oxides of Cu, WS2 and graphite, the composites show low friction coefficient and wear volume loss in air condition. Owing to the fact that graphite loses its lubricity which makes WS2 become the only lubricant, severe adhesive and abrasive wear occur and result in a high value of wear rate in vacuum condition. The formation of the lubricating film on the contact interface between the brush and ring is one of the factors which can greatly affect the wear performance of the brushes. The low contact voltage drop of the composites in vacuum condition is attributed to the high content of Cu in the surface film. This study fabricated a kind of new sliding electrical contact self-lubricating composite with dual-lubricant which can work well in both air and vacuum environments and provides a comprehensive analysis on the lubrication mechanisms of the composite.

Influence of graphite content on sliding wear characteristics of CNTs-Ag-G electrical contact materials

CNTs-Ag-G electrical contact composite material was prepared by means of powder metallurgical method. The influence of the graphite content on sliding wear characteristics of electrical contact levels was examined. In experiments, CNTs content was retained as 1% (mass fraction), and graphite was added at content levels of 8%, 10%, 13%, 15% and 18%, respectively. The results indicate that with the increase of graphite content, the contact resistance of electrical contacts is enhanced to a certain level then remains constant. Friction coefficient decreases gradually with the increase of graphite content. Wear mass loss decreases to the minimum value then increases. With the small content of graphite, the adhesive wear is hindered, which leads to the decrease of wear mass loss, while excessive graphite brings much more worn debris, resulting in the increase of mass loss. It is concluded that wear mass loss reaches the minimum value when the graphite mass fraction is about 13%. Compared with conventional Ag-G contact material, the wear mass loss of CNTs-Ag-G composite is much less due to the obvious increase of hardness and electrical conductivity, decline of friction surface temperature and inhibition of adhesive wear between composites and slip rings.

Effect of La_2O_3 on electrical friction and wear properties of Cu-graphite composites

Sliding friction and wear experiments using Cu-La2O3-graphite composites against Cu-5 wt.%Ag alloy ring were conducted at a constant sliding speed of 10 m/s, a current density of 10 A/cm2 and a load of 2.5 N/cm2. These composites with different La2O3 and graphite contents were fabricated by hot-pressing. Physical and mechanical properties of the composites were examined. Morphologies of the worn surface of composites were observed using optical microscopy. X-ray photoelectron spectroscopy spectra were used to study compositions of the lubricating film. The results showed that with the increasing addition of La2O3, hardness, flexural strength and electrical resistivity increased, but the relative density dropped. The friction coefficient increased with the increasing addition of La2O3. Composite containing 3 vol.% of La2O3 and 37 vol.% of graphite showed the best wear resistance. The main wear mechanisms of composites were abrasive wear, oxidative wear and adhesive wear.

载流滑动摩擦部件表面失效及其修复技术研究进展

滑动电接触部件在电能传递与转换过程中起着举足轻重的作用,其失效和损伤行为带来的安全因素和经济影响重大,因此对其失效机理和修复技术的研究成为当今热点之一.已有众多学者通过试验和计算机模拟仿真等手段研究了电接触部件的表面损伤机制和寿命预测,至今为止,已研究出载流摩擦部件的表面修复技术多达15种以上,修复材料更是有上百种.本文中首先介绍了电接触的基本概念,从有无电流载入2个角度概述了滑动摩擦部件表面失效形式,并从试验研究及仿真模拟研究2个方面对表面损伤机制的研究方法进行了归纳;最后综述了滑动电接触失效部件的表面修复技术和修复材料体系的研究进展,总结了目前滑动电接触部件研究领域存在的问题,提出了利用试验与仿真模拟相结合探究涂层导电耐磨自润滑机理并优化涂层质量的研究思路.

基于电流监测和动态电阻分析的电容器组SF_(6)断路器电寿命评估系统

电容器组SF_(6)断路器电寿命状态监测工作对保障电网安全可靠运行意义重大。文中融合触头磨损计算方法和动态电阻分析法对SF_(6)断路器电寿命进行评估,提出SF_(6)断路器电寿命评估判据,首先基于断路器电流监测数据计算断路器触头磨损,对断路器电寿命状态进行判断预测,再利用动态电阻分析法印证判断出SF_(6)断路器的真实状态,兼顾触头磨损计算法的实时性和动态电阻法的准确性。基于所提判据,研发了一套融合触头磨损和动态电阻的SF_(6)断路器电寿命评估系统。该系统可基于断路器投切数据和动态电阻准确地评估SF_(6)断路器的电寿命,同时在人机交互界面上直观地呈现结果,为工作人员进行断路器状态检修提供辅助决策。

电流强度对QBe2.0电刷丝摩擦磨损性能的影响

本文中研究了QBe2.0电刷丝/滑环摩擦副在不同电流强度条件下的载流摩擦学性能.研究结果显示:随着电流强度的增加,摩擦副平均摩擦系数增加,接触电阻下降,电刷丝磨损表面温度升高,平均硬度降低,电刷丝磨损表面材料软化,磨损面积增大.在摩擦热、电阻热和电弧热的共同作用下,刷丝磨损表面氧化磨损加剧,磨损量增加,粗糙度变大. SEM (扫描电镜)分析显示,磨屑表面出现电弧烧蚀引起的孔洞和熔融喷溅现象,电刷丝磨损面上观察到熔融产生的氧化物颗粒和龟裂现象.随着电流强度的增加,虽然摩擦副摩擦磨损性能下降,但是其接触稳定性和导电性能得到改善.

接触面积对H62/T2弹性接触载流摩擦副性能的影响

针对接触条件对电连接器热插拔条件下性能影响不明的问题,采用H62/T2弹性接触摩擦副,在微-滑动摩擦试验机上,对其进行往复滑动载流摩擦实验,研究了接触面积对H62/T2载流摩擦磨损性能的影响。结果表明:在给定电流为2 A、4 A、6 A条件下,随接触面积的增加,摩擦系数波动性降低,即摩擦过程的稳定性提高,平均摩擦系数和总磨损体积均呈现增大趋势;在电流为2 A条件下,当圆弧半径从1.5 mm增加至5.5 mm时,电流波动性减小,载流稳定性提高,载流效率η从98.26%提高至99.73%。摩擦副的摩擦磨损机制包括磨粒磨损、粘着磨损、电弧侵蚀且多机制耦合作用,随接触面积的增加,以熔融和喷溅为主的电弧侵蚀减少,以犁沟和粘着为主的机械磨损加剧。

表面织构对滑动电接触界面摩擦学行为的影响

目的利用表面织构减摩抗磨的优良特性,将其应用于电接触摩擦表面,探讨它对滑动电接触界面摩擦磨损及电接触可靠性的影响。方法利用激光系统制备2种织构,即方坑型表面织构(SPT)和沟槽型表面织构(GT),并与光滑表面的载流摩擦学信号进行对比分析。利用ABAQUS模拟试验,分析界面接触应力、电压和位移的变化特性。结果随着试验的进行,GT表面的摩擦因数逐渐增大,并与光滑表面达到同一水平(0.7),SPT表面的摩擦因数在整个试验过程中始终较低(0.4)。光滑表面在电接触过程中发生了多频振动现象,2种织构表面的振动信号非常微弱,尤其是SPT表面,仅出现了100 Hz的振动频率。光滑表面和GT表面出现较严重的磨损现象,而SPT表面磨损轻微。有限元分析结果表明,表面织构的存在能够避免应力集中现象,GT表面的应力较大(90MPa),且始终分布在沟槽棱边。结论在电接触状态下,2种织构表面均能不同程度地降低界面的摩擦因数和摩擦力,其中SPT表面的减摩降磨效果最显著。GT表面沟槽棱边的损伤和磨屑堆积是导致其逐渐失去减摩效果的主要原因。模拟分析结果证实,SPT表面织构的存在能避免应力集中,有利于改善磨损和降低振动强度。虽然GT表面的最大应力分布也具有时变特征,但是其值较大,且分布在沟槽棱边,导致沟槽织构的减摩效果逐渐减弱。

进给距离对激光-电复合熔覆层组织及性能的影响

本文采用“激光-电复合丝材熔覆”的方法对机械零件进行修复工艺研究。采用630不锈钢丝材在45#钢表面进行多道单层熔覆实验,研究不同进给距离对熔覆层宏观形貌、微观组织、显微硬度和耐磨损性能的影响。结果表明:随着进给距离的增加,熔覆层与基体结合面变的凹凸不平,熔覆层表面均有杂质小颗粒,熔覆层厚度减小,微观组织为混乱的等轴晶,熔覆层的平均硬度在200 HV上下浮动,摩擦系数呈现先降低后上升的趋势,磨损量与摩擦系数呈现正相关关系,观察其磨痕形貌其磨损形式主要为疲劳磨损和黏着磨损,当前实验条件下进给距离为1.2 mm时,耐磨性能最佳。

核安全级DCS设备危险频率下的电接触摩擦学特性

为研究核安全级分布式控制系统(DCS)设备中的电接触摩擦学特性,对核安全级DCS设备的危险频率进行了评估。建立了一套球面电接触摩擦学试验装置,在危险频率下进行了一系列载流摩擦学试验,探索不同电流作用下界面摩擦磨损特性。研究结果表明,核安全级DCS设备的危险频率为12 Hz;在该频率下,随着输入电流从1 A增大至3 A,摩擦因数呈现先减小后增大的趋势;在大电流作用下,电接触达到失效的时长显著增长;电接触界面表现出划痕、颗粒、微裂纹、磨屑堆积和磨屑飞溅等5种特征;虽然接触区域存在一定的氧化产物,但是只要有足够多的接触区域实现导电通路,界面依然能够保持良好的电接触状态。

载流条件下导电润滑脂轴承的摩擦学性能

选用碳纳米管、纳米导电炭黑作为添加剂,制备了两种导电润滑脂,对两种导电润滑脂进行了滴点、热重、抗氧化性能等理化性能测试,并基于自主研发的轴承载流摩擦试验台进行轴承台架试验,观察并研究了轴承的载流摩擦学特性,探索润滑脂性能对轴承抗电蚀性能的影响。结果表明:加入碳纳米管的润滑脂,滴点并未下降,且热分解温度提高,氧化诱导期延长约44%,摩擦系数及磨斑直径变化不大,磨损体积减小约50%;加入纳米导电炭黑的润滑脂,滴点降低约40℃,热分解温度降低约3℃,氧化诱导期延长约4%,摩擦系数及磨斑直径变化不大,磨损体积减小约90%。两种润滑脂均可有效减小轴承的电蚀程度。

不同表面形貌的接触线对浸金属碳滑板载流摩擦磨损性能的影响

在受电弓-接触网载流摩擦磨损过程中,接触线会产生不同的横截面形状,而接触线形貌的改变可能会影响弓网间的接触关系,进而影响弓网间的载流摩擦磨损性能。为研究不同表面形貌的接触线对浸金属碳滑板载流摩擦磨损性能的影响,利用环-块式高速载流摩擦磨损试验机,研究载流条件下常规形貌、麻点形貌、斜切形貌的接触线与浸金属碳滑板的摩擦磨损性能,比较采用不同形貌接触线时的摩擦因数、电弧能量和浸金属碳滑板的磨损量、表面形貌。试验结果表明:在直流电情况下,常规接触线与浸金属碳滑板组成的摩擦副的摩擦因数最小,滑板磨损量最低;采用斜切形貌接触线时的摩擦因数最大,滑板磨损量最大。通过SEM电镜观测浸金属碳滑板表面的磨损形貌,发现接触线为常规形貌时,滑板以氧化磨损为主,有较多的氧化物产生;接触线为麻点形貌时,滑板以电弧烧蚀和磨粒磨损为主,产生了细小裂纹和烧蚀坑,有较多的磨屑和剥落层出现;接触线为斜切形貌时,滑板以电弧烧蚀为主,有大裂纹和犁沟产生,并且烧蚀区域出现了较多的白色小球。研究表明,当接触线的形貌发生改变时,会导致滑板磨耗增加并加剧接触副电弧放电,从而恶化接触副的状态。因此,当接触线磨损变形严重时,应及时进行更换。

Prediction of electrical contact endurance subject to micro-slip wear using friction energy dissipation approach

Fretting wear is a common cause of failure of an electrical contact(EC). In this study, we analyzed in detail the failure of EC induced especially by sliding using the representative electrical terminals. Furthermore, combining the friction energy dissipation theory, we proposed a prediction model to evaluate the electrical connector endurance(ECE) based on the contact stress and geometrical changes during the wear process obtained from a numerical model. The study helps establish that the friction energy dissipation theory is a powerful tool to analyze a contact failure due to wear. The proposed model proves to be effective in predicting the ECE for all considered cases such as micro-slip amplitude, contact force, overturning angle, superficial layer thickness, and friction/wear coefficients.

变形工艺对MnS/Cu复合材料力电性能及摩擦磨损性能的影响

采用粉末冶金结合热挤压、拉拔、旋锻等变形工艺制备了MnS/Cu自润滑复合材料丝材,利用扫描电子显微镜、X射线衍射仪、电子万能试验机、显微硬度仪、涡流导电仪、摩擦磨损试验机研究了不同变形程度对MnS/Cu自润滑复合材料的显微组织结构、力电性能以及摩擦磨损性能的影响规律。研究结果表明,随冷变形程度的增加,复合材料中MnS颗粒与基体间的界面结合良好,MnS颗粒明显细化,MnS颗粒沿变形方向被拉长,并且呈平行的条带状分布,产生纤维强化效果,抗拉强度由纯铜的284MPa增加到338MPa;经拉拔和旋锻后,复合材料显微硬度逐渐提高,导电率呈先上升后降低的趋势;与纯铜相比,MnS颗粒的添加显著改善了复合材料的摩擦磨损性能,变形加工后复合材料的摩擦系数由挤压态的0.53降低至0.32,磨损量由7.8mg降低至4.2mg。

浸石蜡对碳滑板载流摩擦磨损性能影响研究

为研究在载流条件下浸石蜡对碳滑板摩擦磨损性能的影响,在环-块载流摩擦磨损试验台上试验浸石蜡、未浸石蜡2种纯碳滑板与铜银合金接触线在载流条件下的摩擦磨损性能,并对比碳滑板在不同载荷、滑动速度、电流情况下的表面形貌变化。试验结果显示,浸石蜡对碳滑板载流摩擦磨损性能的影响与电弧烧蚀紧密相关。石蜡及其有机产物加剧电弧烧蚀,石蜡的不完全分解会削弱滑板的载流摩擦磨损性能,通过减小法向载荷、加快滑动速度、增大电流均能显著加剧浸石蜡碳滑板在试验中的电弧烧蚀。浸石蜡碳滑板的摩擦系数的变化规律是:随法向载荷、电流的增大呈现减小的趋势,随滑动速度的增加先增大后减小,60km/h时摩擦系数最大;浸石蜡碳滑板的平均电弧能量、磨耗量随法向载荷的增大呈现减少的趋势,随电流的增大而增加,平均电弧能量随滑动速度的增加而增大,磨耗量随滑动速度的增加先增加后减少,60km/h时磨耗量最大;在低速(40km/h)和高速(80km/h)时浸石蜡增强碳滑板的耐磨性能。