Abstract

The present work investigates the usefulness of milled fly ash, prepared by 60 h mechanical milling of raw fly ash, for the application of brake friction composites. Two specimens were prepared by reinforcing 80 wt% of the raw and milled fly ash with 20 wt% of the phenolic resin. The influence of mechanical milling on the friction and wear performance of the developed raw fly ash composite (RFC) and the milled fly ash composite (MFC) specimens were investigated at varying sliding velocity from 2.6–10.4 ms−1 under 50 N and 150 N using wear and friction monitoring apparatus. It was revealed from the surface morphology of the milled fly ash powder that the large size spherically shaped particles turned in to small size rough shaped particles after ball milling. The average particle size of the raw fly ash reduced from 85.69 μm to 14.61 μm and the specific surface area of the milled fly ash increased by 7.3 times that of the raw fly ash. The tribo-study showed that the average friction coefficient of MFC was found to be noticeably higher than the RFC at all the sliding conditions except at 7.8 ms−1 and 150 N. The increase in sliding velocity increased the weight loss of RFC and MFC specimens at low and high loads. The friction performance of MFC was found encouraging but attention is needed towards decreasing the wear rate when using the milled fly ash for the development of brake friction composites.

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