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Most electric motor brushes fail because, in normal use over a long time period, the brush material simply wears away.

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The material from which the brushes are made is porous and some of the pores are very fine that the material has an exceptional ability to absorb other substances into its structure. Moisture being one, it plays an important part in the functioning of a brush contact by affording a substantial degree of lubrication. The moisture is trapped under the inevitable irregularities of the contact faces of the brushes and forms an outside film on the commutator and it is with this film that the brushes make contact.

Other failures could be due to metal fatigue.

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