Abstract
Production of friction particulate ceramic matrix composites (PCMCs) by powder metallurgy method was carried out using iron 105 μm millscale, 50 μm silica sand, 80 μm magnesia and 53 μm bentonite clay as input materials. Different formulation of the blend of these materials were prepared and the composites were produced. Microstructural, frictional, thermal and wear characterisation were determined using standardised methods. The ceramic composites exhibited very good properties in terms of thermal stability (heat resistance), coefficient of friction (COF) and resistance to wear. The specific values of these properties exhibited by sample D having 12 wt. % iron millscale addition in terms of high resistance to thermal decomposition in the temperature region (0 – 1600 0 C) indicating thermal stability, appreciable high COF (0.59) and very low wear rate of 1.9093 x 10-6 g/m are desirable. The uniform dispersion of the particles as observed in the microstructure and strong bonding/adhesion contributed to the enhancement of the properties. These results are indication that the composite is very suitable for application in areas where high resistance to thermal stress and abrasive wear are required such as the brake assembly of automobiles, specifically the brake pads.
Highlights
The brake system is an important part of automobiles because of the vital role it plays and the brake pads are vital components of the brake system
Without the brake system, driving vehicles could possibly result in road accidents which can endanger the lives of drivers, passengers, and pedestrians
The X-ray Diffractometer (XRD) spectrum of sample D representing samples with iron millscale addition presented in Fig. 4 shows the presence of FeO, mullite (3Al2O3·2SiO2), MgO and spinel (MgAl2O4) occurring at different diffraction angles and intensities
Summary
The brake system is an important part of automobiles because of the vital role it plays and the brake pads are vital components of the brake system. It has been reported that an average automobile driver uses the brake about 75,000 times a year, making the brake one of the most important and overworked parts of vehicles (McPhee, 2007). The ban and gradual phasing-out of asbestos brake pads in many parts of the world due to health reasons have sparked the onset of extensive research and development into safer alternatives. Consumers demand and public awareness led to extensive research and development of brake pads in the early 1990s to find suitable replacement for asbestos brake pads. These have promoted the production of different brake pad materials in the past decade of asbestos-free brake pad revolution. There are several categories of brake pads based on materials constituent such as metallic, semi-metallic and ceramic brake pads (Ma et al, 2012)
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