Utilization of cement bypass dust in the development of sustainable automotive brake friction composite materials

Abstract

• This is our original research work. • The authors have obtained the necessary authority for publication. • The paper has not been published previously, that it is not under consideration for publication elsewhere, and that if accepted it will not be published elsewhere in the same form, in English or in any other language, without the written consent of the publisher. This article explored the potential of cement bypass dust, a waste produced during cement manufacturing, as filler in automotive brake friction composites. Five different cement bypass dust particles (10–25, 88–105, 210–250, 354–400 and 600–700 µm) were used to manufacture non-asbestos/non-copper type friction materials. The composite's tribological properties were obtained from a chase friction testing machine. Maximum friction, fade, and recovery coefficients improve, whereas friction fluctuations and wear resistance of the brake friction composites decrease with cement bypass dust particle size. The worn surface morphology revealed that the cement bypass dust particle size played a considerable role in forming the contact plateaus and deciding the wear behaviour. Multi-objective optimization based on the ratio analysis approach was utilized to determine the composite's performance ranking.