Fabrication and tribological behaviors of copper fiber and carbon fiber reinforced phenol‐formaldehyde resin‐based composite for sliding current collector

Abstract To achieve new current collector (pantograph strip, electric brush) with easy industrialization and high strength‐toughness, carbon fiber and copper fiber reinforced phenol‐formaldehyde (Cu _f /C _f /PF) composite is fabricated by over‐lapping and hot‐pressing processes. Cu _f /C _f /PF composite has compact structure and good interfacial bonding between fibers and resin matrix. Cu _f /C _f /PF composite is superior to carbon skateboard in terms of electrical conductivity, mechanical strength, and friction behavior. As the carbon fiber content increases, fracture failure mechanism of Cu _f /C _f /PF composite transforms from plastic failure into brittle fracture. Wear mechanism is studied by combining electrical contacting and sliding friction, and appropriate arc discharge (2.48%) is benefit for the resin‐based composite to form a smooth tribolayer, but high arc discharge rate (4.83%) rapidly deteriorates wear condition on the worn surface. Highlights Carbon fiber and copper fiber mixing reinforce resin‐based composite. Cu _f /C _f /PF composite has high strength‐toughness and low friction. Fracture failure mode changes to brittle fracture with increasing carbon fiber. Wear mechanism includes electrical contacting and sliding friction. Appropriate arc discharge improve friction performance of resin‐based composite.