Graphites for Carbon Brushes and Carbon Parts

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Who are we?

TIMCAL Group has a strong tradition and history in graphite manufacturing. Its first manufacturing operation was founded in 1908. Today, TIMCAL Group facilities produce and market a large variety of synthetic and natural graphite powders and dispersions of consistent high quality. Adhering to a philosophy of Total Quality Management and continuous process improvement, all TIMCAL manufacturing plants comply with ISO 9001-2000. TIMCAL is committed to produce highly specialized graphite materials for todays and tomorrows carbon brush and carbon parts industries. TIMCAL has an international presence with facilities and commercial offices located in the key markets around the Globe. The Groups industrial and commercial activities are implemented by an experienced multi-national team of nearly 300 employees from seven countries on three continents. TIMCAL Group is a member of IMERYS, a world leader in adding value to minerals. TIMREX Graphites combine technical and economic advantages: their optimal price/performance ratio helps maintain a high quality level in the finished carbon part while, at the same time, reducing manufacturing costs.

About carbon brushes

This document is devoted to the complex field of manufacturing carbon shapes such as brushes, seals and engineering components. The variety of products are as different as the many procedures involved in their production. The carbon parts world is a unique industry having to comply with many and sometimes contradictory requirements such as: Electrical and thermal conductivity. Lubricity and hardness. Mechanical strength and wear protection. Corrosion resistance in - very oftenaggressive environments. These circumstances and the exacting technical demands of this industry call for very well defined high performance raw materials of outstanding consistency.
Bodio, Switzerland

To help our customers make the best selection of raw materials for their needs, TIMCAL Group has produced this document to describe the full range of TIMREX Graphite grades available for this application

Lac des les, Canada

Changzhou, China

Fuji, Japan

Graphite in carbon brushes and carbon parts

BASIC CHEMICAL, PHYSICAL AND APPLICATIONRELATED PROPERTIES
The carbon brushes manufacturers require a carbon with consistent electrical resistance (for high as well as low conductivity purposes), high lubricity, consistent compressibility and predictable absorption level of binder.

Electrical conductivity
The electrical conductivity is strongly influenced by the crystallinity and particle size. A high anisometry of the particle shape leads to an anisotropic behaviour of the electrical conductivity.

Compressibility
Compressibility is dependent on particle size as well as on crystallinity. Other parameters, however, which are related to the texture of the particle also influence compressibility and can be correlated with mechanical properties.

Powders for carbon brushes and carbon parts

Carbon brushes Sliding contacts Current collectors Resin-bonded Pitch-bonded Semi-metallic Sinter-metallic Carbon parts

Absorption behaviour of binder

The absorption behaviour is determined by particle size distribution, surface porosity, particle shape and surface tension between graphite and binder. The knowledge of these properties helps to make the correct selection of graphite and therefore reduces development time. Good processability and constant quality of the final product presuppose a high consistency of the absorption properties of the powders used.

Mechanical seals Bearings Erosion electrodes Electrical resistors

Lubricity Coefficient of friction Wear reduction

High crystallinity and high chemical purity of the graphite powder lead to good lubrication properties. Low friction coefficient and low wear of the commutator are the consequence of these powder characteristics. The hardness of the graphite influences the wear of the carbon brushes. Lifetime of the brushes and the commutator is very often extended by mixing the high purity TIMREX Graphite with small quantities of well-defined polishing additives.

TIMREX Graphites offer many advantages

Predictable synthetic and natural graphites with narrow specifications and unequalled consistent quality due to: monitoring of all production and processing stages, strict final inspection, and clearly defined development processes. Unique properties thanks to the combination of a consistent purity, perfect crystalline structure and well defined texture. Market oriented product development. Application support by TIMCAL engineers.

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TIMREX Graphites for carbon parts

Typical values

Ash (%)

Moisture (%)

Crystallite height Lc (nm)

T Graphite

T 44 T 75 T 15-75 T 150
0 50 100 150
Particle size range d (m)

New

0.07 0.07 0.03 0.09

0.1 0.1 0.02 0.05

> 100 > 100 > 100 > 100

KS Graphite

KS 15 KS 5-25 KS 44 New KS 5-44 KS 75 KS 5-75 TT KS 150

0 50 100 150
Particle size range d (m)

0.05 0.03 0.06 0.02 0.07 0.09 0.06

0.1 0.1 0.1 0.03 0.1 0.02 0.05

> 80 > 100 > 100 > 100 > 100 > 100 > 100

SFG Graphite

SFG 6 SFG 15 SFG 44 SFG 75 SFG 150

0 50 100 150
Particle size range d (m)

New

0.07 0.07 0.07 0.07 0.03

0.1 0.1 0.1 0.1 0.01

> 100 > 150 > 200 > 200 > 200

GB Natural Graphite
0 50 100 150
Particle size range d (m)

GB 99/6 GB 98/75

0.6 1.3

0.1 0.1

> 400 > 400

Particle shape

Tribological and mechanical properties

Advantages and applications

angular flakes, microporous

- high toughness - good lubrication properties

- low friction coefficient - low wear of the counterpart and low self-wear - good transfer-film formation - medium electrical conductivity - medium density of brushes and parts - suitable for pitch-bonded and resin-bonded brushes

irregular spheroids

- medium toughness - good lubrication properties

- low friction coefficient - low wear of the counterpart - good transfer-film formation - high electrical conductivity - suitable for pitch-bonded and resin-bonded brushes

strong anisometric flakes, needles

- low toughness - very good lubrication properties

- very low friction coefficient - low wear of the counterpart - extreme good formation of transfer-film - very high electrical conductivity - excellent wettability with organic binders - excellent compressibility - high transverse rupture strength - suitable for pitch-bonded, resin-bonded and metallic brushes

flakes

- very good lubrication properties

- very low friction coefficient - low wear of the counterpart - very high electrical conductivity - suitable for semimetallic and metallic brushes

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Powder Properties
Graphite powders and their influence on carbon parts
TIMCAL Group is in the position to provide analytical and test results for graphite powders and the corresponding graphite compacts. Based on this information, conclusions can be drawn from the properties of the final products and vice versa.

Powder properties
Purity Ash content Moisture Trace elements Crystalline structure Crystallinity Texture BET surface area Xylene density Scott density Oil absorption Particle size Particle size distribution Laser diffraction, sieving methods Thermal stability

Properties of binder-free graphite compacts

Compact density Springback Mechanical strength Electrical resistivity Oil absorption In the following pages there are some of the results of experimental work carried out on TIMREX Graphite at our Technical Centre.

Properties of final products

Wear Compact/brush Commutator/counterpart Friction coefficient Transfer film Brush temperature Density Commutation Electrical properties

Powder Properties:
Compact density
Compact density is a parameter describing the structure density available at given pressing conditions. The density of compact obtained is influenced by spring back and expansion of the compact after shaping and demoulding from the press. The difference between xylene density and compact density indicates the degree of interparticular porosity in the compact and compressibility of the powder. The minimum binder quantity required to achieve porefree dense composite materials can be calculated. As the figures show, compact density is influenced by pressure, particle size, crystallinity and other physical properties of the graphite particles. At high pressure values (p>5 t/cm 2 ) the compact density becomes nearly pressure independent. For a small particle size, the compact density is hardly influenced by the particle structure. A high crystallinity results in a high compact density.

Density of graphite compacts

Die: 30 x 20 mm

2.2

GB
2.0 1.8

SFG

KS
1.6 1.4
Density (g / cm3) Pressure: 2.5 t/cm2

1.2 1.0 0 20 40 60 80 100 120 140 160

Particle size d90 (m)

Pressure

2.2

SFG 44
2.0 1.8 1.6 1.4
Density (g / cm3)

KS 44 T 44

1.2 1.0 0
Pressure (t / cm2)

Die: L = 30 mm W = 20 mm

10

Mass = constant W Density of compacts

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Powder Properties:
Springback
Measuring method
The springback is a reading giving the resilience of compacted graphite powder. A defined amount of dry powder is poured into a die. After inserting the punch and sealing the die, air is evacuated from the powder. Pressure is applied (p=0.477 t/cm2) and the powder sample thickness is measured. Thickness is measured again after pressure has been released.

Springback of graphite compacts

Die diameter: 20 mm

25

20

KS
15

Conclusion
Springback and compact density of graphite powders are physically connected parameters, which give information about the compactibility of powders and dimensional stability of compacts in any pressing direction. Springback is influenced by pressure, particle size, crystalline structure ad other properties. Crystalline structure is the main parameter. A high crystalline structure results in low springback. Compacts produced from powders having a low springback can be easily formed and pressed with greater accuracy.

Pressure: 0.477 t/cm2

10

Springback (%)

SFG
5

GB

0 0 20 40 60 80 100 120 140 160

Particle size d90 (m)

25
Pressure meter

20
Punch Seal Metering element

T 44

15

KS 44

Die

10

SFG 44
Springback (%)
Compact Vacuum line

0 0
Pressure (t/cm2)

0.2

0.4

0.6

0.8

Pressure

Spring back

SB =
H(p) H(0)

H (0) - H (p) H (0)

x 100 %

Powder Properties:
Transverse rupture strength
Measuring method
The transverse rupture strength is measured on graphite compacts pressed to bars with size of 50x12x6 mm and 30x20x10 mm without binder. Other measurements carried out on test pieces with dimensions of 50x12x8 mm show comparable results.

Transverse rupture strength of compacts

Bar: 30 x 20 x 10 mm

10

Conclusion
Transverse rupture strength (Arbitrary units)

The transverse rupture strength corresponds to the compressibility of powders, characterised by compact density, springback and expansion. Compact density and internal cracks influence the measured mechanical strength. The mechanical strength can be enhanced by increasing the compaction pressure and by using graphites of smaller particle size. With the increase of the degree of crystallinity the mechanical strength also increases.

GB

SFG

Pressure: 2.5 t/cm2

KS T

0 0 20 40 60 80 100 120 140 160

Particle size d90 (m)

7
Load

SFG 44
6 5 4 3 2 1 0 0
Pressure (t / cm2)

KS 44

Compact

Transverse rupture strength (Arbitrary units)

T 44

L L = Distance between the supporting rods (20 mm)

10

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Powder Properties:
Electrical resistivity
Measuring method
The electrical resistivity is measured on defined compacted test bars (50x12x6 mm, compacting pressure: 2.5 t/cm2). In order to be able to distinguish between the various graphites a very accurate and reliable method has to be used. The four-point method applied for these measurements greatly reduces the possibility of errors due to poor contacts.

Electrical resistivity of graphite compacts

Bar: 50 x 12 x 6 mm

3 2.5 2 1.5

KS

Pressure: 2.5 t/cm2

Conclusion
Information about the electrical resistance of compacted graphite powders is helpful for raw material selection from different graphite types. The T and KS types and mixtures of T and KS are mostly used for medium and highly ohmic brushes. SFG and GB types provide best performance in semi-metallic and sintermetallic brushes, where a high electrical conductivity is required.

1 0.5 0 0 20 40

GB SFG

60

80

100

120

140

160

Particle size d90 (m)

The results of resistivity measurement of KS 75 and T 75 are somewhat misleading. It has to be taken into consideration that the compactability of the graphite affects the electrical resistivity because of microcracks and porosity. As already shown, these two graphites are relatively difficult to compact due to the coarse particle size. Other investigations have shown that in compounds containing a high amount of graphite the resistivity decreases with increasing particle size. A B C

A = Measuring electrodes B = Current carrying electrodes C = Silver contact adhesives D = Ohmmeter

Powder Properties:
Oil absorption (DBP)
Measuring method
The oil absorption test is a special centrifugation method showing high reproducibility, developed by TIMCAL. A special centrifuge tube is filled with 0.5g of TIMREX graphite powder and then covered with dibuthylphthalate (DBP). After centrifuging for 90 minutes at a relative acceleration of 453g, the tube is weighed and the oil absorption of 100g of powder is calculated (based upon the weight increase of the 0.5 g sample).

Oil absorption of graphite powders

Oil: dibuthylphthalate DBP

200

150
Oil absorption (g DBP / 100 g graphite)

100
KS 5-44

KS SFG
T 15-75

Conclusion
The oil absorption is a very useful tool to estimate the binder requirement. Various fundamental properties such as: Particle size Bulk density BET Crystalline structure as well as the wetting angle affect the absorption properties.

T
SFG 150

50

KS 5-75 TT

0 0 20 40 60 80 100 120 140 160

Particle size d90 (m)

TIMREXGraphite has found its place in the field of carbon parts as a reliable, high quality product. Many problems can be solved thanks to the broad range of TIMREX Graphites. Our specialists will be glad to help you in the selection of the most suitable product for your application.
Acceleration

Tube Centrifugation DBP Sample Filter Sieve

Leading the way.

Commercial Offices Manufacturing Plants Distributors / Agents (full list available on request)

TIMCAL Ltd. Head Office of the Group CH-6743 Bodio, Switzerland Phone: +41 91 873 20 10 Fax: +41 91 873 20 19 info@ch.timcal.com TIMCAL America Ltd. Representative Office 29299 Clemens Road 1-L Westlake, Ohio 44145, USA Phone: +1 440 871 7504 Fax: +1 440 871 6026 info@us.timcal.com

TIMCAL Deutschland GmbH Representative Office D-56564 Neuwied, Germany Phone: +49 2631 890 737 Fax: +49 2631 890 752 info@de.timcal.com Changzhou TIMCAL Graphite Corp. Ltd. 188# Taishan Road, Hi-Tech Zone, Changzhou 213022 P.R. China Phone: +86 519 5100801 Fax: +86 519 5101322 info@cn.timcal.com STRATMIN Graphite Inc. 2500 Boul. Daniel-Johnson Suite 906 Laval, Quebec Canada H7T 2P6 Phone: +1 450 686 8630 Fax: +1 450 686 8725 info@stratmin.com

Offered by your local Distributor/Agent:

TIMCAL Japan K.K. Representative Office 7F Sagamiya Bldg. 6 Ichibancho Chiyoda-ku Tokyo 102-0082 Japan Phone: +81 3 3511 2078 Fax: +81 3 3511 2077 info@jp.timcal.com TIMCAL in France Representative Office Tour Maine Montparnasse 33, avenue du Maine FR-75755 Paris Cedex 15, France Phone: +33 1 4538 3850 Fax: +33 1 4538 3851 info@fr.timcal.com

2001 TIMCAL Ltd., CH-Bodio No part of this publication may be reproduced in any form without the prior written authorisation of TIMCAL Ltd. Printed in Switzerland.

CB-01 10.2001