Brake Pad Materials Research Articles

Napier natural fibre used as reinforcement polymer composite: As asbestos free brake friction material

The importance of Natural fibre in reinforce composite material has been increased due to good mechanical properties and favourable to environment. Many previous reports have warned that asbestos, Kevlar and trending materials have side effect on human health. So now there is need to find out the substitute of these materials. In this direction Napier grass fibre has been used as reinforced brake pad material. The 5–20% Napier fibre used in brake pad composites. The Napier brake pad composites have showed good mechanical properties. The fade has showed improved results for 5% Napier fibre composites. Recovery has showed its modified value at 20% composition. The Thermal stability was found maximum at 20% Napier fibre composition.

Effect of hexagonal boron nitride (h-BN) addition on friction behavior of low-steel composite brake pad material for railway applications

In this study, low-steel composite friction materials containing different amount of h-BN were developed for railway vehicles. Addition of h-BN has no considerable effect on mechanical properties of the matrix structure. However, h-BN addition significantly affects friction and wear properties of the matrix material. While h-BN increases coefficient of friction of samples at low disk surface temperatures, it has a reverse effect after the temperature reaches to a critical level of 250–300 °C. Also, addition of 1.5 wt% h-BN to the matrix brings about more stable changes in friction coefficient during the braking periods under the extreme conditions as compared to the h-BN-free sample. Furthermore, low h-BN addition into the matrix results in better lubricity properties at relatively high temperatures.

Relationship Between Mechanical Behavior and Microstructure Evolution of Sintered Metallic Brake Pad Under the Impact of Thermomechanical Stress

Abstract It is well known that on the brake pad material, the triptych microstructure-properties-solicitations is the key to better understand the phenomena caused by braking stress. The challenging issues are the evolution of this triptych, i.e., the impact of thermal stress and mechanical stress on the microstructure which undoubtedly induces changes in properties. In order to solve the issues without tackling them in all their complexity, this study proposes an experimental approach where physics is decoupled but inspired by the braking sequence in terms of applied temperature gradient and braking loads. Two experimental tests were carried out. The first one is the thermal solicitation test where a temperature gradient from 400 °C to 540 °C was applied to the material. The second one is the thermomechanical test where a compressive load at 20 MPa was applied under the same thermal gradient. The experiment time is fixed for 2 min, equivalent to the time of one braking stroke. The referred material is sintered metallic composite, which is widely used as the brake pad material for high energy railway. As a result, it shows that coupled thermomechanical stress has a greater impact on material properties than decoupled one. This impact is related to the microstructure where graphite inclusions play an important role.

Explosive atmosphere ignition source identification during mining plant suspended monorail braking unit operation

Coal dust and methane explosions are some of the most common causes of mining disasters in hard coal mines all over the world, and research continues to be conducted with the purpose of understanding the mechanisms of an explosion, explosion prevention and risk reduction. This article presents the test methodology as well as virtual and bench test results for a braking unit, which constitutes one of the main components of a suspended monorail transport system. The design work and virtual and bench testing were performed as part of a European research programme. The tests were conducted in a dedicated specialist test facility. The tests were based on Polish standard PN-G-46860:2011, concerning braking trolleys employed in mining plant suspended railway systems. The tests also factored in the requirements for non-electrical devices intended for use in explosive atmospheres, including braking systems, as defined in standard PN-EN ISO 80079-36:2016, harmonised with the ATEX directive. The test scope encompassed braking unit operational component temperature measurements using thermal imaging and the contact method, as well as braking distance measurements. Further tests involved virtual simulations of brake pad heating. The tests employed the finite element method (time-varying calculations). Results obtained over the course of numerical calculations indicate that brief brake pad friction face heating, even up to a temperature exceeding 200C, does not result in inward heat propagation towards the brake pad material. This is also confirmed by the measurement results. However, under real conditions, the braking unit would be engaged only during an emergency situation, which would not lead to exceeding the permissible brake shoe material temperature values.

Statistical and artificial neural network technique for prediction of performance in AlSi10Mg-MWCNT based composite materials

The present research paper deals with AlSi10Mg alloy/MWCNT metal matrix composite brake pads with varying weight percentages. The Development of new brake pad materials has been done at compacting load (10 Tons) and sintering temperature (450 °C) using the powder metallurgy process. The input parameters of 40 N normal load, 500 rpm, 150 °C pin temperature as the near-optimal combination of parameters for minimum wear and maximum coefficient of friction compared to other test conditions have been observed by the design of experiment (DOE). The overall average percentage error in the output against experiment output is less than 1%. Analysis of variance (ANOVA) indicates that load is a most significant factor than speed and temperature for wear and CoF. Artificial Neural Network (ANN) is used to develop a prediction model to calculate wear and coefficient of friction for different loads, pin heating temperature and speed. The model developed shows a strong correlation with experimental output. The experimental and predictive model developed from artificial neural network are strongly correlated with a correlation factor of 0.99447 for the training algorithm of Levenberg-Marquardt technique. ANN prediction model and Taguchi L16 array reveal that the experimental and predicted data for mass loss and CoF have less than 3% and 4% error, respectively. The closeness between the artificial neural network and experiment results enhances the scope of ANN for predicting the wear of materials. The model will help engineers to predict the failure of components with reference to running time and can be applied in automobile or manufacturing sectors to study wear, thus saving their time and cost in carrying out experiments.

Development and tribological studies of a novel metal‐ceramic hybrid brake disc

AbstractCeramic matrix composite (CMC) friction materials show promising tribological properties. Typically, carbon ceramic brake discs consist of a C/SiC rotor which is joined to a brake disc bell. Within this work, a novel metal‐ceramic hybrid brake disc, consisting of C/SiC friction segments which are mounted by screws onto an aluminum carrier body, was designed and investigated. A prototype was built which was tribologically tested with three different brake pad materials, LowMet reference, modified SF C/SiC as well as C/C. A constant starting sliding velocity of 20 m/s and braking pressures of 1, 2, and 3 MPa were investigated. To simulate emergency braking conditions 10 consecutive brake applications were carried out in close succession for each brake pad material and braking pressure. The C/C brake pad material showed the highest average coefficient of friction followed by the LowMet and C/SiC material. However, the wear rates of the C/C and LowMet material were orders of magnitude higher compared to the C/SiC material.

Mechanical and the effect of oil absorption on tribological properties of carbon-based brake pad material

This research focuses on the mechanical and effect of oil absorption on the tribological properties of carbon-based brake pad material (CBP). Carbon-based materials, including those at a nanosize, are combined for developed brake pad material. The mechanical properties related to wear properties such as compression strength, stiffness, hardness, and absorption properties were determined. The effect of oil absorption on the tribological properties of carbon-based materials was investigated. The obtained properties are compared with that of a ceramic-made brake pad (commercial). The experimental results show that the mechanical and absorption properties of the developed brake pad material varied with the combination and quantity of additives used to develop each brake pad material. CBP material offered higher performance than ceramic-made brake pads. The CBP material showed a higher shear strength of about 110%, 51% enhanced compressive strength, 35% greater modulus, comparative statistical hardness, 98% lesser water intake, and 97% oil absorption rate than ceramic made brake pad. The tribological properties of friction material after soaked in oil proved that absorption properties affect tribological properties of brake pads, which can be attributed to the oil content in the material system. The effect of oil uptakes on wear rate and friction of the commercial brake pad was higher than CBP materials, implying that the loading of carbon-based materials is a viable way to reduce absorption rate, which helps in increasing brake pad performance. The improved properties are suggestive of materials combinations that may be used to develop brake pad materials.

Statistical and computational analysis of an environment-friendly MWCNT/NiSO4 composite materials

Abstract A brake pad material has been developed with multiwall carbon nanotube (MWCNT) and Nickel sulfate (NiSO4) to increase the heat transfer rate and better manufacturability. The maximum hardness of brake pad sample is found at 15 Ton compacting load and 150 °C sintering temperature. The performance of developed brake pad is compared with conventional brake pads. Scanning Electron Microscope (SEM) with Energy Dispersive X-Ray (EDX), high resolution transmission electron microscopy (HRTEM), X-ray diffraction (XRD), gas sorption analyser (GSA) and thermal property analyser (TPA) are used to measure the distribution of elements, compound analysis, porosity distribution and thermal properties analysis respectively. The wear particles (mass loss) are less in the developed brake pad. The results show that developed brake pad material is superior compared to market available brake pads. An artificial neural network (ANN) model has been developed to predict the mass loss and coefficient of friction (CoF). The input parameters of 300 rpm, 50 N load and 125 °C temperature are the near optimal parameters combination for minimum wear and maximum CoF as observed by the design of experiment (DOE). The ANN and DOE results are verified with experimental findings. An ANSYS model has also been developed to study the temperature variation with time. The model has also compared with experimental results and found the 1% error.

Tribological Properties of SiCp/A356 Composites Against Semimetallic Materials under Dry and Wet Conditions

Due to their low density and excellent friction performance, SiCp/A356 composites are increasingly used to produce brake disks for metro and intercity trains. To evaluate how wetness affects its tribological properties and surface morphologies, the friction and wear behavior of SiCp/A356 composites against a semimetallic brake pad material was investigated using a ring-on-disk configuration under dry and wet conditions. The coefficients of friction and wear rates were measured, and the surface morphologies of the third body layer were observed during tests. The test results showed that the coefficient of friction was consistently maintained between 0.35 and 0.4 for varied loads and velocities under dry surface conditions, whereas the values fluctuated dramatically under wet conditions. The third body layer was created during the rubbing process. Analysis of the third body layer revealed that it consisted of a mixture of SiCp/A356 composites, semimetallic materials and their oxides. The surface morphologies of the third body layer tested under dry conditions were continually distributed with shallow microplows and black adhesion pits. However, those under wet conditions were discontinuous and contained uncovered regions, cracks or peeling for varied loads and velocities. In contrast to dry conditions, an evolutionary mechanism model was proposed to describe the effect of humid conditions on tribological behavior, considering the effect of water on the third body under humid conditions. The tribological properties of SiCp/A356 composite brake disks under humid conditions, such as rain and snow, should be noted.

Experimental Investigation of Thermal and Tribological Characteristics of Brake Pad Developed from Eco-Friendly Materials

This study presents an analysis of the thermal stability and frictional performance of a brake pad material, with banana fiber and phenolic resin as modified binder, on a specially designed disc brake test rig. Four different brake pad composites were prepared by varying the wt% of banana fiber and phenolic resin without varying the other ingredients. The brake pad samples were fabricated as per the Indian standard, corresponding to a light four wheeler vehicle. The samples of brake pad were subjected to density, hardness, thermal conductivity, thermogravimetric analysis (TGA), differential thermogravimetric analysis (DTG), Fourier transform infrared spectroscopy (FTIR), friction, fade and specific wear rate analysis. The thermal stability of brake pad samples was examined by TGA and DTG. The disc brake test setup was used for evaluating the friction and fade performance of brake pad samples as per SAE J661. The disc brake test rig and the standard used for analyzing the performance of brake pad samples proved to be reliable and effective. The results revealed that the incorporation of banana fiber is a promising alternative, for the enhancement of thermal stability of binders in the brake friction material.

The influences of high temperature on tribological properties of Cu-based friction materials with a friction phase of SiO2/SiC/Al2O3

Cu-based friction materials have better tribological properties, high mechanical strength, and excellent thermal conductivity; therefore, they are widely used as friction materials in high-speed rail brake systems. However, with the remarkable increase in running speed of high-speed trains, a great amount of energy and high temperature are induced in the brake system; therefore, new challenges are generated for brake pad materials. In this paper, Cu-based friction materials were prepared with the addition of various hard particles as the friction phase, in order to obtain a good high temperature tribological performance. The experimental results showed that the Cu-based friction materials with addition of hard particles have moderate mechanical strengths and proper tribological properties. The temperature effects on the tribological behaviors of friction materials were investigated. The coefficient of friction (COF) for friction materials with addition of hard particles increased with temperature, resulting from the integrated effects of friction film, graphite, and material softening. The variation trends of the wear loss and wear rate with temperatures are similar to those of COFs, which are significantly reduced with the addition of hard particles.

Analisis Sifat Mekanik Komposit Bahan Kampas Rem Dengan Penguat Serbuk Kayu Jati Dan Serbuk Kuningan

The purpose of this research for analyze composite material reinforced tesk wood powder and brass powder and epoxy resin matriks as brake pads material. The mix of composite brake pads divided into three kinds are Spesimen A, Spesimen B, Spesimen C, with different material composition next made to be mixing process, compacting, and sintering. This testing done with way test violence through Brinell method, test of wear rate use tool of Ogoshi high speed universal wear testing machine produce data of highest violence composite owned by Spsesimen A with score 10 HBN and highest wear rate owned by Spesimen C with score 0.0004 Kg/mm2. Composite material teak wood powder and brass powder and epoxy resin matriks have character of mechanics if composite have score of big violence so wear rate will more low and otherwise if composite have score of little violence so the wear rate will more high.

Development of low cost brake pad material using asbestos free sugarcane bagasse ash hybrid composites

The brake pad material was fabricated using asbestos-free agro-waste sugar cane bagasse ash (SCBA) at low cost by a compression molding technique. SCBA in varying proportions (0%, 5%, and 10% weight) was added to the composite mixture containing epoxy resin as a binder. The size of the SCBA particle was 300 µm. The fabricated brake pad was subjected to mechanical, physical, and tribological analyses. The obtained results were compared with conventional asbestos-based brake pad material. The results showed that the sample having 10% SCBA as filler content has high tensile strength, flexural strength, density, low water, and oil absorption. Also, the hardness test and impact test results revealed the suitability of SCBA in brake pad material.

Present knowledge and perspective on the role of natural fibers in the brake pad material

This is a review article on brake pads produced using natural fiber. The various International attempts to address environmental issues and the necessity to safeguard the environment have given light to research emphasizing natural fibers usage in various applications, including automotive brake pads. The usage of asbestos in the brake pads is to be avoided because of the high risk in health it possesses, such as being carcinogenic and unsafe to the environment. Thus researchers are interested in natural fiber due to its excellent properties, very cheap, readily available, non-toxic, etc. In this investigation, the mechanical and tribological property of a non-asbestos brake pad is compared with the asbestos brake pad. These cases illustrate non-asbestos brake pads' ability to achieve substantial improvements in wear rate, Coefficient of friction, Hardness, and moisture absorption compared to conventional brake pads overbroad, and Several factors contribute to these improvements.

Tribological performance of Hemp fiber reinforced phenolic composites: A brake pad material

Tribological performance of Hemp fiber reinforced phenolic composites: A brake pad material

Manufacturing of continuous fiber reinforced sintered brake pad and friction material

Copper-based brake pad material is fabricated by powder metallurgy methodology. The developed brake pad material has steel fibers and fly ash as reinforcement to increase the strength and hardness. A methodical approach is followed, where the microstructure is obtained and subsequently the micro hardness values were obtained. After which, wear test is conducted considering various parameters including sliding velocity, normal loads. The tribological parameters namely wear rate and coefficient of friction are evaluated. The wear mechanism of the developed material is deduced from advanced metallurgical characterization. The material is optimized for maximizing the performance by permuting different composition of materials and orientations of matrices.

Mechanical Properties of Hybrid Polymers for Break pad Applications.

Non wear out brake emission is one of the significant issue concerns with health and the environment. In brakes performance, wear debris is released in the atmosphere and pollute the environment. The brake pad is classified into two categories mainly asbestos and non-asbestos. As per the report of WHO and Environment Protection Agencies, some of the metals oxidized and produces toxic gaseous. Toxicity leads and creates a bad effect on human health. This work focuses on remedies over environmental and health issues because of brake pad emission. It is important to reduce the percentage of toxic elements at source and develop novel material compositions that are less dangerous to the environment and human health. Also, it satisfies all requirements of a brake pad material as per international standards. From this investigation, we found an alternate material for brake bad applications. The natural fibers reinforcement material is zero toxic. So, the materials will not create any environmental and human health issues.

Study on wear analysis of substitute automotive brake pad materials

ABSTRACT The objective of this work is to study the wear analysis of brake pad in braking operation to estimate the weight loss and wear rate of different bake pad materials used in automotive applications. The braking system’s in an automotive slow down or stop the automobile entirely by transforming its kinetic energy to heat energy. During breaking due to rapid interaction between the pad and rotor interface generates high temperatures, hence the brake pad must absorb heat rapidly to survive at high temperatures with no wear. This work investigates and deliberates innumerable environment-friendly and healthy substitute materials to asbestos. Generally brake pad friction substance is made of different materials such as binders, filler content, additives and reinforcements, to satisfy the specifications and adjust their percentage effects on the wear properties. Over the previous few years, the brake pads have been manufactured of asbestos material with enough electrical, tribological as well as physical properties, but that causes cancer and many other health issues, and therefore its use is redundant. In this work three specific mixtures are used with adjusted ratios of ingredients and observed their impact on the tribological characteristics. More weight loss (8–10%) is observed for the asbestos material as compared to the non-asbestos material. The wear rate increases with increase in contact pressure between the brake surfaces under dry condition. As the wear rate of non-asbestos material and CL3003 material is less as compared to asbestos, hence these can be a good option for the replacement to asbestos.

Development of fly ash based friction material for wind turbines by liquid phase sintering technology

Fly ash based sintered materials are identified as potential brake pad materials for wind turbines. However, fly ash based friction materials fabricated through conventional techniques results in more porosity and undesirable tribological properties. This study attempts to develop liquid phase sintering technology for fly ash using Cu as a liquid phase sintering agent. The study presents a comprehensive analysis of the evolution of microstructure, microhardness, and tribological performance of the specimens sintered in Argon and Air environment.

Porosity and tribological performance analysis on new developed metal matrix composite for brake pad materials

This paper deals with the development and performance of metal matrix composite for brake pad with NiSO4 as filler materials in terms of manufacturing ability and a good amount of porosity. Microstructure and surface roughness of the samples are analysed using scanning electron microscopy (SEM) and atomic force microscopy (AFM) respectively. Energy dispersive x-ray (EDX) and scanning transmission electron microscopy (STEM) are used to detect elemental distribution in the sample. X-ray diffraction (XRD) compound phase analysis is used to find the presence of compound in the brake pad samples. The analysis shows that brake pad compounds are present in original form. Thermal property analyser shows that thermal conductivity and thermal diffusivity of developed brake pad are more than market available brake pads. Sufficient amount of porosity is observed with gas sorption analyser (GSA) which is useful for conductive and convective heat transfer and preventing the overheating of brake pad system. The design of experiment and experimental analysis leads to the conclusion of near optimum parameter combination for maximum coefficient of friction and minimum wear rate. This paper reveals that the developed brake pad is better than selected market available composite brake pads on basis of hardness, thermal property, porosity distribution, and tribological performance analysis. The developed brake pad may be one of the good options for the commercially use in near future.