摘要

A novel type of resin-based electrical contact material (RECM) was prepared for the first time via the second curing of a sulfonated graphene/waterborne epoxy resin after pore formation. The carrying-current wear behavior of the RECMs was tested on a durability test bed of a HMC-2500 type electric power tool, and microstructural characterization of the RECMs surface was carried out using AFM, SEM, TEM and XPS. The results show that the carrying-current wear rate of the RECMs impregnated with sulfonated graphene was approximately 56% of that of the RECMs not impregnated with sulfonated graphene, and it was also lower than that of the original carbon brush (widely used in the market). Moreover, AFM analysis indicated that the introduction of sulfonated graphene can significantly improve the surface hardness and toughness of RECMs. It was also found that sulfonated graphene could restrain the stress growth in situ in the micro-crack region, which contributes to the formation of a slight "fish scale" friction film on the wear surface during the wear process. Furthermore, it can effectively improve the integrity of the contact surface between the friction pairs and reduce any abnormal wear and resist arc erosion wear. The research results provide guidance and a theoretical basis for the research and design of high performance electrical contact materials.