Enhanced current-carrying tribological properties of copper-based microporous friction pairs containing slow-release polyaniline conductive grease

The wear of friction pairs, especially under current-carrying conditions, significantly reduces equipment performance and service life due to electric arc erosion. This study employs laser surface texturing on copper blocks to create microporous structures, with polyaniline grease synthesized in situ based on these microscale reactors to reduce material wear and arc erosion. Results demonstrate that this method effectively fills the microporous with grease, ensuring grease supply under starved lubrication and long-term stable operation of friction pairs. The textured sample with a diameter of 140 µm at 6 A exhibits a 74.3 % reduction in coefficient of friction, 2.7 times less wear, extremely low arc erosion, and an electrical contact resistance of only 2.5 mΩ, maintaining stable tribological performance even after 21,600 cycles.