Study on Current-Carrying Friction Characteristics and Corrosion Resistance of Carbon Brush/Collector Ring by Copper–Graphene Electrodeposition Process

The collector ring/carbon brush assembly of a hydrogenerator set is a critical component for transmitting excitation current into the self-exciting winding. Its operating environment necessitates excellent corrosion resistance and current-carrying frictional properties. The surface condition and material composition of the collector ring are key factors influencing the performance of the brush/ring interface. Coatings have proven effective in enhancing both tribological and corrosion-resistant characteristics. In this study, copper/graphene composite coatings were fabricated via electroplating, and the effects of graphene deposition rate on current-carrying friction characteristics were systematically investigated to optimize electroplating parameters. The results showed that the composite coating reduced contact resistance by 32.58% and friction coefficient by 37.59%. Electrochemical and immersion tests were conducted to evaluate the corrosion behavior under varying pressure and current density conditions. The results revealed that the optimal corrosion resistance was achieved under 1 N pressure and 12 A/cm2 current density. The copper/graphene composite coating demonstrated superior corrosion resistance compared to uncoated samples. In summary, the electroplated copper/graphene composite coatings exhibit excellent current-carrying frictional performance and corrosion resistance, offering a promising solution for enhancing the durability and efficiency of hydrogenerator collector rings.