Brake Pad Samples Research Articles

Friction, wear, and hardness properties of hybrid vehicle brake pads and effects on brake disc roughness

Abstract Considering the emerging importance of a sustainable green environment today, this study contributed to realizing resource sustainability by expanding the use of natural materials in the brake pad sector. Brake pads used in vehicle applications were developed using natural components, and their effects on brake performance properties were observed in brake pad samples containing four different amounts of natural components with additive rates of 0 %, 4 %, 8 %, and 12 %. Tests were conducted on the pad tester to determine the samples’ friction coefficient and wear rates. Hardness measurements were made with a Shore D measuring device. Average and maximum disc roughness were measured to determine the effect of brake pads on the brake disc. Microscopic analyses were performed with a scanning electron microscope. The results showed that using tamarind seed powder in the pad content created a synergy with alumina, brass powder, and graphite as friction modifiers, and the friction coefficient increased slightly. Considering the emerging importance of a sustainable green environment today, it has been determined that using natural materials contributes to realizing resource sustainability by expanding its application in the brake pad sector and positively affecting the brake system disc roughness.

Analysis and Characterization of Composites for their potential use in Disc Brake Pad

Brake pads are crucial for vehicle safety, converting kinetic energy to halt motion. They come in types like organic, semi-metallic, ceramic, and metallic. Beyond automotive, brake pads find application in industries such as aerospace, railways, manufacturing, and wind energy for controlled deceleration and safety. This study is primarily concerned with the quality and appropriateness of ceramic brake pads for automotive applications, which are an essential aspect of braking systems for vehicles. The performance characteristics of ceramic brake pads are well established, and this study explores the variables affecting their quality. Under high pressure, brake pad samples are prepared in the study using Powder Metallurgy (PM), which guarantees superior mechanical qualities by removing interface bonding problems. The samples are then sintered at 2850. Hardness, temperature resistance, wear resistance, and Electron Dispersive Spectroscopy (EDS) analysis are all included in the evaluation to ascertain the make-up and distribution of the materials in the brake pad. EDS sheds light on the degree of sintering and the presence of reinforcements. Heat resistance is evaluated using controlled thermal testing, while wear resistance and hardness are determined through Rockwell hardness testing and wear tests, respectively. These measurements are validated for use in automotive disc braking systems for vehicles and motorcycles. The findings are more reliable thanks to statistical analysis done with MINITAB. The study highlights research gaps in environmentally friendly materials, emerging technology impacts, and long-term brake pad durability.

An investigation on the performance of vehicle brake pads developed from Cortaderia selloana based biomass

AbstractNowadays, researchers are making intense efforts to develop biomass-based industrial products. This study developed low-metallic and asbestos-free samples based on Cortaderia selloana (12–15% and 18% ratios), a natural species, to contribute to the brake pad field. The developed samples’ friction coefficient and wear rate experiments were carried out on a brake pad test device with a load of 1 MPa and a disk rotation speed of 6 m/s, according to the TS555 standard. Scanning electron microscopy and electron-dispersive x-ray analysis were performed on the worn surfaces of the samples. According to the results obtained, the wear rate increased while the average friction coefficient decreased in the brake pad samples using 18% Cortaderia selloana content in the sample content. In scanning electron microscopy analysis, primary and secondary plateau formations were observed on the worn surfaces of all samples. At the same time, samples containing 15% and 18% Cortaderia selloana also showed signs of abrasive wear. High friction coefficient and low wear rate are expected for brake pads to be used in automobiles. In general, the friction of brake pads must be within the range, and it is always necessary to balance the friction to avoid driver discomfort. However, except for some racing applications, a high coefficient of friction is only sometimes desirable, which can cause rotor wear problems. As a result of this research, a consistent friction coefficient and low wear rate for the brake pads with the brake pad sample containing 12% Cortaderia selloana.

A comparative study of original equipment manufacturer brake pads using tribological testing and hybrid ranking for enhanced decision making and cost effectiveness

Tribological test and hybrid ranking techniques are employed to evaluate brake pads from original equipment manufacturers for Indian passenger cars. The study was conducted for four brake pads designated as OE1, OE2, OE3, and OE4. The assessment integrates the analytical hierarchy process with various ranking methods including Extension Evaluation Method, Complex Proportional Assessment, Preference Selection Index, and Technique for Order of Preference by Similarity to Ideal Solution. Brake pad samples undergo testing according to the standard IS2742 part 1-4 of 1994, generating crucial performance parameters such as performance coefficient of friction, hot coefficient of friction, normal coefficient of friction, fade percentage, recovery percentage, variation in coefficient of friction, wear thickness loss percentage, wear mass loss percentage, and time taken to reach maximum temperature. These performance metrics are technically analyzed and ranked using hybrid ranking techniques to enhance the decision-making process. The results show that OE4, a budget-friendly brake pad ranked first, is the best performer. OE2, a more expensive alternative, is placed second, and OE1 and OE3, which are more affordable possibilities, are ranked third and fourth, respectively. This research serves as a valuable resource for selecting brake pads for Indian passenger cars, especially in scenarios where technical specifications and cost-effectiveness are crucial considerations.

Investigation of the effects of halloysite nanoclay on friction and wear behavior of automotive brake pads

Abstract They are produced with the desired performance with friction modifiers, reinforcements, lubricants, binders, and fillers used in various properties in brake pads. This study investigated the effect of the use of halloysite nanoclay material used in different sectors as a filler in brake pads. The hot-pressing method produced brake pad samples containing 10–15 % and 20 % halloysite nanoclay. A full-scale brake pad tester determined the samples’ friction coefficient and wear rates. Scanning electron microscopy (SEM) and 3D profilometer analyses were performed on the worn sample surfaces after the experiment. As a result, it was determined that the halloysite nanoclay samples met the desired brake lining properties.

The effect of huntite and barite mineral-based polymer composite brake materials on friction and braking performance

Mineral materials are used in brake pad polymer composites at different rates, and positive results are obtained in tests conducted with the brake pads produced. This study produced brake pad polymer composites based on huntite and barite minerals. The materials forming the samples were mixed in a kinetic-type mixer, pressed using the hot molding method and prepared for the experiments with the curing process as the final process. Density, friction coefficient, wear rate and TG-DSC mass loss tests were performed on the samples. After the friction coefficient test, microscopic analyses of the brake pad samples were performed using a scanning electron microscope, and the surface roughness was measured using a three-dimensional profilometer. In the friction coefficient, hardness and mass loss analyses, values similar to those reported in the literature were obtained for all the samples. As a result, it was determined that the huntite and barite mineral-based polymer composite brake friction materials produced for automobiles exhibited performance following the brake pad characteristics.

Analysis of the wear and friction of brake pad added cashew and ulexite using ANSYS

The aim of the current research is a comparison of the wear ratio on the brake pad with the real values and the simulation values. Therefore, brake pad samples prepared from cashew and ulexite mixtures were used. The variation of total deformation on and wear ratio is investigated with using Ansys. Also, in this study, the brake pad, and disc were designed using Catia v5. Data input of pressure is selected 1.05 MPa on pad surface samples and 500 seconds on a brake disc rotating at 6 m/s. This analysis was made for 5 different samples. On the other hand, we are not getting clear results because of some limitations such as creating materials and unknown some material properties. With some approaches, real results were approached. Results showed that the simulation results are linear to the values according to the real values. The results that are found on software, approximately between +%9 and -%14. Also, it was observed that wear occurred in the center of the pad. It was thought that this wear could be reduced by distributing the pressure applied to the surface of the pad.

Performance evaluation of brake pads developed using two different manufacturing methods

AbstractThe aim is to study the effect of several distinct manufacturing processes, parameters and ingredients on the physical, mechanical and frictional characteristics of brake pad developed using hand lay method (sample 1), brake pad developed using hot compression method (sample 2) and commercial brake pad (sample 3). The non asbestos brake pad samples were compared with the selected commercial brake pad sample using pin on disc test set up. Results showed that friction performances of all three samples were insensitive to water and oil absorption test. Sample 2 had better mechanical properties and greater wear resistance than other two samples which are attributed to use of hot press method of manufacturing the composite and selecting the carbon‐based ingredients. Sample 1 maintained high coefficient of friction even though manufactured with the help of hand lay method. Both fabricated brake pads are stable upto the temperature 220 °C without any weight loss and degradation. Brake pad surfaces showed different shape wear debris and plateaus significantly affecting the friction characteristics. Finally, the test results indicated that both fabricated brake pad samples have potential braking characteristics to be used as a brake pad material.

Effects of fly ash introduction on friction and wear characteristics of brake pads

Fly ash is a waste matter generally emitted abundantly from chimneys of the production facilities and should mostly be recycled. In this context, this study reveals the tribological effects of fly ash on brake pad components by doping the fly ash in basic brake pad matrix with various weight fractions of 30% (S30), 35% (S35) and 40% (S40) by reducing aluminum powder in the pad matrix. According to the results, as the fly ash concentration increases in the matrix, density and hardness of the structure were prone to decrease to an extent. Water immersion technique was used to determine density values and specially modified pin-on-disc tribotester was utilized to measure coefficient of friction (CF) and specific wear rate (SWR) values between brake pad samples and the cast iron rotating disc. Among prepared samples, maximum average reduction in density and hardness were observed to be by 3.97% and 10.67%, respectively. S30 depicted the minimum CF of 0.32 and maximum CF of 0.43 was performed by S40. Maximum specific wear rate was observed for S40 subtending to an increase of 8.67% from that of S30 to S40. Results showed that, though higher escalation in CF as the fly ash fraction elevates in the matrix, wear rates did not show a dramatic increase which is an indication of effectiveness of fly ash in brake pads in terms of braking performance and long term durability.

Synergistic effect of bismuth III sulfide and iron sulfide in the tribological performance of brake friction composite

Metal sulfides play a major role in determining the friction and wear performance of the brake friction composites. The usage of the combinations of metal sulfides improves tribological performance compared to its individual metal sulfides in the formulation of friction material. In this work, the effect of the Bismuth III sulfide and Iron disulfide combination was evaluated against the tribological performance in the formulation of the friction materials. Six brake friction pads were developed by properly balancing the weight percentage of Bismuth III sulfide and Iron disulfide in the formulation. The tribological performance of the friction liners was studied using a chase tribo-meter following the IS2742 test protocol. The worn surfaces of the brake pad samples were examined for its surface morphology and elemental behaviour using a Scanning electron microscope and an Energy-dispersive x-ray spectroscope. It was observed that the partial replacement of the Bismuth III sulfide with Iron sulfide improves the friction and fade performance. The abrasive nature of the Iron sulfide in the friction pad increases the coefficient of friction and causes the high wear loss beyond the ratio of 4:6 of the mixed sulfides. A statistical approach named preference selection Index was employed to rank the brake friction materials based on the multiple performance criteria.

Investigation of Friction and Wear Behavior of Composite Brake Pads Produced with Huntite Mineral

Huntite (CaMg3(CO3)4) is a calcium magnesium carbonate mineral and is a mineral in the dolomite group. Although studies on Huntite's flame retardant raw material feature stand out, it is used in the paint industry, and the industrial sectors such as plastics, pol-ymers, special rubbers, and pharmaceuticals. In this study, experiments were carried out by producing brake pad samples in different mixing ratios from huntite mineral and glass fiber, kaolin, graphite, phenolic resin, and rubber powder to be used for brake pads in the automotive industry. Friction coefficient and wear rate which is an important fea-ture for the produced pad samples were measured in the brake pad testing device. Ac-cording to the Archimedes principle, the specific gravity and disc roughness values formed by the brake pad samples on the disc were measured with a roughness tester. According to the measured values, the highest average friction coefficient was obtained in the A45 sample, the minimum wear value was obtained in the A10 sample, and the minimum roughness change was obtained in the A25 sample.

Coconut waste fiber used as brake pad reinforcement polymer composite and compared to standard Kevlar‐based brake pads to produce an asbestos free brake friction material

AbstractThe awareness of eco‐friendly materials has increased the demand for natural fibers. Natural fibers have many advantages over other materials like short growing time, easy availability, cheap, and eco‐friendly with good mechanical properties. WHO has announced that trending materials have many side effects on the environment and on human beings. Asbestos has been already a proven cause of many cancers. In this research Coconut fiber, a natural fiber has been used in the brake pad as a brake friction material. The different percentage of Coconut fiber 2‐8 wt% was used to develop new brake pad samples and that compared to standard brake pad material (Kevlar with 2%–4%). The results of physic‐mechanical properties reveal that tensile modulus, ultimate compressive strength, impact energy, and flexural strength were showing good performance at 2% polymer composites matrix, and ultimate tensile strength, shear strength, and proof showing good performance at 6% fibers contents in brake pad composites. Thermal stability for Coconut fiber fibers composites increases with increases the fiber contents.

Dry sliding behavior of carbon-based brake pad materials

The brake pad plays a crucial role in the control of vehicle and machinery equipment and subsequent safety. There is always a need for a new functional material with improved properties than existing ones. The present research study was carried out to develop a new brake pad material made up of polymer nanocomposite for enhanced physical, mechanical, and frictional characteristics in comparison to existing brake pad materials. In this study, polymer nanocomposite samples were developed and their physical properties namely density, water-oil absorption, and porosity were evaluated. Mechanical hardness of developed samples was estimated with Vicker’s hardness tester. Frictional characteristics of samples and wear values determined with pin or disc apparatus. Dry sliding behavior was examined by conducting multiple trials with sliding speed in the span of 2-10 m/s and load were changed from 20 N to 100 N to discuss the effect of velocity, the effect of nominal contact pressure and the effect of sliding distance on friction and temperature parameters. Morphology of prepared brake pad samples was characterized with the Scanning electron microscope. Scanning electron micrographs of brake pad surfaces showed different shape wear debris and plateaus significantly affecting the friction characteristics. Developed samples along with commercial specimens show excellent resistance to water and oil absorption. Thus obtained results for evaluated polymer nanocomposite brake pad samples demonstrate their potential for brake pad applications.

Performance analysis of SiC-Ni-P nanocomposite electroless coated brake pad

ABSTRACT This research article deals with the comparative performance analysis of the nanocomposite SiC-Ni-P coating on the edge and chamfer parts of the brake pad. The coating is used to provide a smooth surface and prevent overheating, wear, and tear. The electroless coating method is performed on the brake pad initially with Ni-P and later with SiC to enhance the durability. Field Emission Scanning Electron Microscopy with EDAX mapping is used to measure the spread of the elements in the brake pad samples and verify the presence of Si, Ni, and P elements in the coated sample. Atomic Force Microscopy (AFM) is used to analyze the surface roughness of coated and uncoated samples. Experiments are designed using a Taguchi L16 orthogonal array to study the influence of process parameters on responses for coated brake pads. The best results were obtained at a near-optimal parametric combination (20 N, 1.57 m/s, and 150°C). Artificial Neural Network (ANN) has also been used to predict the output. The ANN output has also been verified with the experimental results. Coated brake pad gives more impressive results based on compressive strength and tribological performance.

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.

Investigation of the Use of a New Binder Material in Automotive Brake Pad

In this study, the usability of waste banana peel and banana tree bark with a fibrous structure as binders was investigated experimentally. Ac-cordingly, the amount of fiber, friction regulator, filler, abrasive and sol-id lubricant is fixed, and three different brake pad samples were pro-duced by adding 10% banana peel and 10% banana tree bark powders by reducing the amount of phenolic resin. Production was carried out by conventional dry mixing method and powder metallurgy method. For this, firstly a homogeneous mixture of all ingredients is provided. The mixture transferred to the mold was pressed at room temperature firstly. Samples obtained as the first form were subjected to hot pressing in the mold again. Thus, the ability of the resin to hold all the materials together has become active. Finally, the samples were cleaned and prepared for the tests. To examine the braking performance of the produced pads, a specially designed brake tester with brake disc was used. Friction, wear, density and hardness tests of the pads were made. SEM images of friction surfaces of pads were taken and microstructures were examined. The ef-fect of using banana waste as a binder in the brake pad on braking per-formance was evaluated. As a result, it was observed that banana wastes are alternative materials that can be used in brake pads.

Investigation on the Physical/Mechanical Properties of NAO brake friction Composites by using Kenaf fiber

Natural fibers utilization for various applications is in increasing trend owing to its eco friendliness and ease availability. In this work the effect of kenaf fibers as key ingredient is studied for brake pad applications. The Consequences of kenaf fiber as reinforcement is studied for physical and mechanical properties. Kenaf fibers have been added in 3 different weight percentages from 0 wt% to 15 wt%. The developed composites were evaluated as per industrial standards. Properties such as density, ash content,hardness,water absorption and compressibility have been studied in this work. The brake pad samples were prepared and subjected for testing for various physical and mechanical properties. All the tests have been carried out by standard industrial procedure. Based on the results it can be clinched that the properties of hardness, density and content of ash density, decreased to certain extent and other properties such as compressibility, porosity and water absorption capacity increased with fiber loading of kenaf fiber. It can be concluded that the fiber loading has impact on the performance of fibers.

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.

Wear response of non-asbestos brake pad composites reinforced with walnut shell dust

With automobile numbers continuing to increase, competition among manufacturers of brake pads is also increasing along with the search for additives to serve as alternatives to the materials presently being used. In addition to the cost of the additives used, another important consideration in choosing materials is that they should be safe for the environment and human health. This study investigated the effect on braking performance of brake pads produced using walnut shell powder as a natural additive material. Two different types of brake pad samples were produced using 3.5 (2A) and 7% (2B) walnut shell dust in the contents. A commercial Clio brake tip was used as the reference (CO). The produced brake pads were subjected to thermal conductivity, friction wear, density, hardness and water and oil absorption tests and microstructure analysis. A Chase type device was used for wear friction tests, and the results were obtained according to SAE-J661(Brake Lining Quality Test Procedure) standards. The experimental data were compared with those of the commercial brake pads, and the performances of the natural additive brake pads were evaluated. The addition of walnut shell was shown to be compatible within the composition and exhibited a positive effect on the friction coefficient.

Frictional Characteristics of Brake Pad Materials Alternate to Asbestos

Nevertheless, asbestos though having ample physical and tribo-mechanical properties is being banned worldwide due to its health hazardousness. Most importantly, any material replacing asbestos should have comparable friction properties. This paper aims at comparative study of frictional characteristics of asbestos base and asbestos free brake pad materials. A total of three friction materials namely AF-22 (metallic based), CL-3003 (fine brass based) and DM-6 (asbestos based) were compressed and moulded into a sample. Experiments were performed using dedicated test set-up based on Pin-on-disc principle. Coefficient of friction was compared for three materials at different conditions of sliding velocity and pressure. Experiments were performed using Taguchi’s L27 orthogonal array. Ranking of the parameters have been done based on experimental results and S/N ratio analysis. The elemental composition of materials was measured by EDS technique. Scanning electron micrographs of brake pad samples were tested at different magnifications. Further investigations to evaluate wear rate, stopping distance under simulative test conditions are suggested.