Brake Wear Particles Research Articles

An active-type dust collector that reduces brake wear particle (BWP) emission

An active-type dust collector that reduces brake wear particle (BWP) emission

Investigations of airborne tire and brake wear particles using a novel vehicle design

Non-exhaust emissions have become an increasingly important issue as their levels continue to rise and the health effects of particulate matter (PM) are more widely discussed. To address this issue, a vehicle demonstrator with integrated emission reduction of tires and brakes was developed as part of the Zero Emission Drive Unit Generation-1 (ZEDU-1) project. This novel concept includes the removal of tire road wear particles (TRWP) with a strong ventilation/filtering system and an enclosed multi-disk brake, making it a suitable tool for the investigation of non-exhaust emissions. Particle number (PN) and particle size distribution (PSD) measurements down to 2.5 nm were performed on a chassis dynamometer and on a test track. Due to the low background concentrations on the chassis dynamometer, it is possible to distinguish between tire and brake wear and to characterize even a small number of particle emissions. It could be shown that about 30 % less particles are emitted by the vehicle, when using the novel multi-disk brake instead of the conventional brake. The highest TRWP emissions were collected during acceleration and harsh braking. Characterization of the collected particles using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) revealed diverse particle shapes and differences between particles generated on the dynamometer and on a test track.Graphical

Brake Wear and Airborne Particle Mass Emissions from Passenger Car Brakes in Dynamometer Experiments Based on the Worldwide Harmonized Light-Duty Vehicle Test Procedure Brake Cycle

Brake wear particles, as the major component of non-exhaust particulate matter, are known to have different emissions, depending on the type of brake assembly and the specifications of the vehicle. In this study, brake wear and wear particle mass emissions were measured under realistic vehicle driving and full friction braking conditions using current commercial genuine brake assemblies. Although there were no significant differences in either PM10 or PM2.5 emissions between the different cooling air flow rates, brake wear decreased and ultrafine particle (PM0.12) emissions increased with the increase in the cooling air flow rate. Particle mass measurements were collected on filter media, allowing chemical composition analysis to identify the source of brake wear particle mass emissions. The iron concentration in the brake wear particles indicated that the main contribution was derived from disc wear. Using a systematic approach that measured brake wear and wear particle emissions, this study was able to characterize correlations with elemental compositions in brake friction materials, adding to our understanding of the mechanical phenomena of brake wear and wear particle emissions.

Size distribution of brake wear particulate matter based on a brake dynamometer investigation

A brake dynamometer has been modified to accurately study the concentration and size distribution of wear particles in different testing conditions. The test equipment was a charged low-pressure impactor ELPI+ from Dekati, Finland. 29 test conditions were defined based on speed, acceleration and initial brake temperature. Additionally, five different types of brake pads were selected for testing to provide a more comprehensive understanding of the particle size distribution characteristics of brake wear particles. The results showed that the mass of BWPs was unimodal in the range of 0.01–8.11 μm, with peak sizes at 2–5 μm or >8.11 μm, and particles of 0.5–3.0 μm accounted for an average of 49.09% of the total particulate mass, while particles with sizes of 3.0–8.11 μm accounted for an average of 49.72% of the total particulate mass. The number of particles emitted by abrasion had a bimodal distribution, with one in the nucleation mode and the other in the accumulation mode, with peak sizes of <10 nm and 1 μm, respectively; the nucleation mode particles accounted for an average of 60.11% of the total PN10, and the ultrafine particles accounted for an average of 82.15%.

Automotive braking is a source of highly charged aerosol particles

Although the last several decades have seen a dramatic reduction in emissions from vehicular exhaust, nonexhaust emissions (e.g., brake and tire wear) represent an increasingly significant class of traffic-related particulate pollution. Aerosol particles emitted from the wear of automotive brake pads contribute roughly half of the particle mass attributed to nonexhaust sources, while their relative contribution to urban air pollution overall will almost certainly grow coinciding with vehicle fleet electrification and the transition to alternative fuels. To better understand the implications of this growing prominence, a more thorough understanding of the physicochemical properties of brake wear particles (BWPs) is needed. Here, we investigate the electrical properties of BWPs as emitted from ceramic and semi-metallic brake pads. We show that up to 80% of BWPs emitted are electrically charged and that this fraction is strongly dependent on the specific brake pad material used. A dependence of the number of charges per particle on charge polarity and particle size is also demonstrated. We find that brake wear produces both positive and negative charged particles that can hold in excess of 30 elementary charges and show evidence that more negative charges are produced than positive. Our results will provide insights into the currently limited understanding of BWPs and their charging mechanisms, which potentially have significant implications on their atmospheric lifetimes and thus their relevance to climate and air quality. In addition, our study will inform future efforts to remove BWP emissions before entering the atmosphere by taking advantage of their electric charge.

A Practical Approach for On-Road Measurements of Brake Wear Particles from a Light-Duty Vehicle

Brake wear particles are generated through frictional contact between the brake disc or brake drum and the brake pads. Some of these particles may be released into the atmosphere, contributing to airborne fine particulate matter (PM2.5). In this study, an onboard system was developed and tested to measure brake wear particles emitted under real-world driving conditions. Brake wear particles were extracted from a fixed volume enclosure surrounding the pad and disc installed on the front wheel of a light-duty vehicle. Real-time data on size distribution, number concentration, PM2.5 mass, and the contribution of semi-volatiles were obtained via a suite of instruments sub-sampling from the constant volume sampler (CVS) dilution tunnel. Repeat measurements of brake particles were obtained from a 42 min bespoke drive cycle on a chassis dynamometer, from on-road tests in an urban area, and from braking events on a test track. The results showed that particle emissions coincided with braking events, with mass emissions around 1 mg/km/brake during on-road driving. Particle number emissions of low volatility particles were between 2 and 5 × 109 particles/km/brake. The highest emissions were observed under more aggressive braking. The project successfully developed a proof-of-principle measurement system for brake wear emissions from transient vehicle operation. The system shows good repeatability for stable particle metrics, such as non-volatile particle number (PN) from the solid particle counting system (SPCS), and allows for progression to a second phase of work where emissions differences between commercially available brake system components will be assessed.

Feasibility of Measuring Brake-Wear Particle Emissions from a Regenerative-Friction Brake Coordination System via Dynamometer Testing

Emissions of brake-wear particles are commonly associated with vehicular traffic. We investigated the feasibility of quantifying brake-wear particle emissions under realistic vehicle driving and braking conditions with a currently used regenerative friction brake coordination system. We used a braking system installed in commercially available plug-in hybrid electric vehicles and found that it reduced emissions by 85% for PM10, 78% for PM2.5, and 87% for particle numbers (PNs) compared with the system installed in vehicles with internal combustion engines. Brake friction work showed a linear relationship with PM10 and PM2.5. Nanoparticle PM emissions tended to increase slightly with regenerative braking but did not contribute significantly to the overall PM percentage. The emission events of high concentrations of nuclei-mode particles (<20 nm in diameter) in electric vehicle brake assemblies designed for regenerative braking use under high-temperature, high-load braking conditions with full-friction brakes. The nuclei-mode particles amplified the PN emissions and led to high variability. In strict regulatory certification tests where measurement reproducibility and stability are required, it is appropriate to measure PNs under brake conditions appropriate for the actual use of electric vehicles rather than under full-friction brake conditions or to remove particle measurements smaller than 20 nm.

Iron Oxide and Hydroxide Speciation in Emissions of Brake Wear Particles from Different Friction Materials Using an X-ray Absorption Fine Structure

Iron (Fe), the main component of non-exhaust particulates, is known to have variable health effects that depend on the chemical species of iron. This study characterized the possible contribution of iron oxides and hydroxides to airborne brake wear particles under realistic vehicle driving and braking conditions with different brake pad friction materials. We found significant differences in wear factors and PM10 and PM2.5 emissions between non-asbestos organic (NAO) and European performance (ECE) brake pads. Iron was the dominant contributor to PM10 and PM2.5 brake wear particles for both NAO and ECE. The iron concentration ratio in the particle mass (PM) was comparable to the disc-to-pads ratio measured by wear mass. The fact that magnetite, which is of interest with respect to health effects, was less abundant in NAO than in ECE suggested that tribo-oxidations occurred in NAO. Metallic iron is generated not only from abrasive wear but also from tribo-chemical reduction with magnetite as the starting material. We found that there were differences in PM emissions between brake friction materials, and that the phase transformations of iron differed between friction materials. These differences were apparent in the distribution of iron oxides and hydroxides. Heat, tribo-oxidation, and tribo-reduction are intricately involved in these reactions.

Regenerative braking system effectively reduces the formation of brake wear particles

Brake wear particles (BWPs) are considered one of the most significant non-exhaust particle emission sources from motor vehicles. Previous studies have primarily focused on BWPs from conventional fuel vehicles (CFVs), with limited research available on BWPs from new energy vehicles (NEVs). We developed an independent BWP emission testing system applicable to NEVs and conducted BWP emission tests on representative NEVs and CFVs under various testing cycles via a chassis dynamometer. The BWP emission characteristics of the NEVs equipped with regenerative braking system significantly differed from those of gasoline vehicles. For transient emission characteristics, gasoline vehicles exhibited higher peak concentrations during brake events than brake drag events, while those with regenerative braking exhibited the opposite feature. Under continuous braking, the concentration of ultrafine particles emitted by NEVs was reduced by more than 3 orders of magnitude compared to gasoline vehicles. In terms of single-particle morphology, BWPs could be mainly divided into three categories: carbonaceous particles, iron-rich particles, and mixed metal particles. We obtained realistic emission characteristics of BWPs from NEVs, which could provide data support and a scientific basis for the formulation of relevant emission standards and control measures in the future.

Airway contraction and cytokine release in isolated rat lungs induced by wear particles from the road and tire interface and road vehicle brakes

The dominant road traffic particle sources are wear particles from the road and tire interface, and from vehicle brake pads. The aim of this work was to investigate the effect of road and brake wear particles on pulmonary function and biomarkers in isolated perfused rat lungs. Particles were sampled from the studded tire wear of three road pavements containing different rock materials in a road simulator; and from the wear of two brake pad materials using a pin-on-disk machine. Isolated rat lungs inhaled the coarse and fine fractions of the sampled particles resulting in an estimated total particle lung dose of 50 μg. The tidal volume (TV) was measured during the particle exposure and the following 50 min. Perfusate and BALF were analyzed for the cytokines TNF, CXCL1 and CCL3. The TV of lungs exposed to rock materials was significantly reduced after 25 min of exposure compared to the controls, for quartzite already after 4 min. The particles of the heavy-duty brake pads had no effect on the TV. Brake particles resulted in a significant elevation of CXCL1 in the perfusate. Brake particles showed significant elevations of all three measured cytokines, and quartzite showed a significant elevation of TNF in BALF. The study shows that the toxic effect on lungs exposed to airborne particles can be investigated using measurements of tidal volume. Furthermore, the study shows that the choice of rock material in road pavements has the potential to affect the toxicity of road wear PM10.

Direct measurement of brake and tire wear particles based on real-world driving conditions

With implementing vehicle emission control policies, tailpipe particulate emissions have been gradually controlled, and the relative contribution of non-tailpipe particulate emissions, such as brake and tire wear, has further increased. A unified and scientific method for sampling non-tailpipe particulate matter (PM) emissions is essential to improve the accuracy of the emission characteristics and factors. This study proposes a novel sampling method based on real-world driving conditions to obtain information on emissions and extract characteristic conditions for tire and brake pad wear. We extracted 200 representative braking segments for simulation experiments based on road type, initial and final velocities, temperature, and deceleration rate. Two standard test cycles to simulate the tire wear conditions of the front and rear wheels were constructed based on velocity, lateral, and vertical forces. Under the real-world driving condition test cycle, the emission factors of PM2.5 and PM10 for brake wear particles of passenger vehicles were 2.66 mg/km and 11.65 mg/km, respectively. In contrast, the emission factors of PM2.5 and PM10 for tire wear particles were 0.21 mg/km and 1.27 mg/km, respectively. Moreover, this study provides insights and basic data for localizing and improving the emission model, which can enhance its applicability and accuracy.

Laboratory and on-road testing for brake wear particle emissions: a review.

Brake wear emission is a significant contributor to vehicle-related particulate matter, especially in areas with high traffic density and braking frequency. Only recently, non-exhaust emissions from car brake wear have been regulated under Euro 7 regulation, which introduces emission limits for both brake and tires. It also introduces a standard brake particle assessment procedure which includes sampling procedure and measurement techniques defined in the Global Technical Regulation on brakes from light-duty vehicles up to 3.5 t. Over the years, various experimental setups have been tried leading to non-comparable results. The brake wear particle emissions, expressed as emission factors, are mostly estimated as particle mass or particle number and described using different units (e.g., mg/stop brake, mg/km brake; particle number/cm3) making the comparison between studies very difficult. The aim of the present literature review is to present the state-of-the-art of different experimental methods tuned for assessing brake wear emissions, including electric vehicles. The experiments are carried in close, semi-closed, and open systems, and depending on the experimental design, different sampling methods are applied to reduce particle transport loss and guarantee the efficiency of the particle sampling. Driving condition (e.g., speed and applied pressure), formulation of brake materials, and friction temperature have been found to strongly affect the emission characteristics of brake particles, and this needs to be considered when designing study procedures. The findings reported in this review can be beneficial to policy makers and researchers.

Physical and chemical characteristics of particles emitted by a passenger vehicle at the tire-road contact

Non-exhaust emissions are now recognized as a significant source of atmospheric particulate matter and the trend towards a reduction of conventionally fueled internal combustion engine vehicles on the road is increasing their contribution to air pollution due to lower exhaust emissions. These particles include brake wear particles (BWP) and tire-road contact particles (TRCP), which are composed of tire wear particles (TWP), road wear particles (RWP) and resuspended road dust (RRD). The goal of this study has therefore been to design an original experimental approach to provide insight into the chemical composition of particles emitted at the tire-road contact, focusing on the micron (PM10–1μm) and submicron (PM1–0.1μm) fractions. Through this characterization, an examination of the different TRCP generated by different materials (tire, road surface, brake system) was conducted. To achieve this, TRCP were collected at the rear of the wheel of an instrumented vehicle during road and track tests, and a SEM-EDX analysis was performed. Our experimental conditions have allowed us to demonstrate that, at the individual particle scale, TRCP are consistently associated with road dust materials and particles solely composed of tire or road materials are practically non-existent. The contribution of BWP to TRCP is marked by the emission of Fe-rich particles, including heavy metals like Ba, Mn and Cr. TWP, which result from rubber abrasion, consist of C-rich particles abundant in Si, Zn, and S. RWP, mainly composed of Al, Si, Fe, and Ca, can be either part of RRD or internally mixed with emitted TWP. The findings of this study highlight the substantial role of RRD to TRCP emissions under real driving conditions. Consequently, it underscores the importance of examining them simultaneously to achieve a more accurate estimation of on-road traffic emissions beyond the vehicle exhaust.

Effects of oral exposure to brake wear particulate matter on the springtail Orthonychiurus folsomi

Most of the heavy metals in urban environments derives from road traffic, particularly from tyres and brake wear (non-exhaust emission sources). These pollutants contaminate the soil, where several organisms have a primary ecosystem role (e.g., springtails, ants, earthworms). Springtails (Collembola) are soil-dwelling animals regulating soil fertility, flow of energy through above- and below-ground food webs, and they contribute to soil microbial community dispersion and biodiversity maintenance. In this study we investigated the ecotoxicological effects of oral exposure to particles emitted from brake pads and cast-iron brake discs in the euedaphic collembola species Orthonychiurus folsomi under laboratory conditions. Our results showed that chronic exposure to brake wear particles can have sub-lethal effects both at low and high concentrations and it can cause histological alterations. Here, SEM-EDX was applied to observe the particulate and we found its chemical markers in the gut and faeces of collembola, while histological analysis detected alterations of the digestive and reproductive systems and of the abdominal fat body at high concentrations.

Comprehensive Analysis of Current Primary Measures to Mitigate Brake Wear Particle Emissions from Light-Duty Vehicles

Exhaust regulations and improved exhaust gas treatment systems have already initiated the trend that brings emissions from brakes and tires to the forefront of traffic-induced particulate matter. The health and environmental relevance of particulate matter has resulted in regulators, industry, and research institutions prioritising the mitigation of non-exhaust particle emissions. To this end, under the umbrella of the United Nations Economic Commission for Europe World Forum for Harmonisation of Vehicle Regulations (UNECE WP.29), the Working Party on Pollution and Energy (GRPE) mandated the Particle Measurement Programme Informal Working Group (PMP-IWG) to develop a Global Technical Regulation (GTR) for measuring brake dust. The standards and procedures defined within the GTR should eventually form the basis for the introduction of a Euro 7 limit value for brake emissions. The purpose of this measurement campaign is to provide an exemplary overview of the emission behaviour of wheel brakes and friction pairings currently available on the market and to identify possible reduction potential with regard to particulate emissions. All measurements were carried out taking into account the draft GTR valid at the time of execution. For the investigations, brakes were selected using the example of different vehicle classes, brake concepts (disc and drum brake), vehicle axles (front and rear axle), and alternative friction materials (brake disc and pads/shoes). Thus, the use of wear-resistant discs and improved brake pad compositions are able to achieve significantly lower emissions. In addition, the measurement of brake dust emissions from vehicles with different levels of electrification was considered. Electrical braking was modelled and applied to the Worldwide Harmonised Light-Duty Vehicles Test Procedure (WLTP) Brake Cycle, which has demonstrated high emission reduction potentials depending on the electrification level.

Interlaboratory Study on Brake Particle Emissions—Part I: Particulate Matter Mass Emissions

The Particle Measurement Programme Informal Working Group (PMP-IWG) coordinated a global interlaboratory study (ILS) on brake wear particle emissions with the participation of 16 testing facilities. Two articles present the main outcomes of the ILS: (I) Particulate matter mass (PM), and (II) Particle Number (PN) emissions. The test matrix covered a wide variety of brake systems and configurations. The tested disc brakes were found to emit PM2.5 and PM10 that varied between 0.8–4.0 mg/km and 2.2–9.5 mg/km per brake, respectively, depending on the type of brake and the applied testing load. The drum brake emitted much lower PM due to its enclosed nature. Almost 37–45% of the emitted PM falls in the fine particle size with this fraction being higher for the drum brake. On the other hand, almost 50–65% of the total brake mass loss falls in particle sizes larger than 10 μm or gets lost before being measured. The most important loss mechanisms for PM in the proposed layout are being discussed. Finally, the PM measurement variability and lab-to-lab reproducibility are investigated.

Size effect of CrFe particles on tribological behavior and airborne particle emissions of copper metal matrix composites

Brake wear particles emitted from vehicles during friction have become an important source of airborne particulate matter (PM) that causes adverse health effects. Particle emissions might be reduced by optimizing the composition of friction materials. Effects of CrFe particle size on tribological behavior and airborne particle emissions of copper metal matrix composites (Cu-MMCs) were investigated using a pin-on-disc tribometer at sliding speeds ranging from 2.5 to 5.0 m/s. The results indicate that the frictional properties, particle emission behavior and worn surface characteristics of Cu-MMCs were strongly influenced by the size of CrFe particles. With decreasing the CrFe particle size, the friction coefficient was relatively stable at 3.8 m/s, decreased gradually at 2.5 m/s, and decreased first then increased at 5.0 m/s. Basically, Cu-MMCs with medium-sized CrFe particles (100–150 mesh) produced the highest levels of particle emissions, followed by Cu-MMCs with large-sized CrFe particles (60–100 mesh), and then Cu-MMCs with small-sized CrFe particles (150–250 mesh) in succession. The level of particle emissions from Cu-MMCs increased substantially with increasing sliding speed. The obtained results were explained considering the evolution of the worn surface characteristics during the friction process.

Interlaboratory Study on Brake Particle Emissions Part II: Particle Number Emissions

The Particle Measurement Programme (PMP) informal working group co-ordinated a global interlaboratory study (ILS) on brake wear particle emissions with the participation of 16 laboratories in 2021. Two articles present the results of the ILS: (I) particulate matter mass (PM) and (II) particle number (PN) emissions. The test matrix covered different brake systems, including ECE and NAO pad materials with grey cast iron discs and a drum brake. Regarding PN, the study measured the total particle number from approximately 10 nm to 2.5 µm (TPN). Some testing facilities measured solid particle number emissions (SPN) in parallel. The mean TPN concentrations ranged from 9.1 × 108 #/km/brake to 1.1 × 1010 #/km/brake. TPN and SPN emission levels were comparable, except for one lab that measured very high volatile particle emissions for one brake system. The minimum and maximum SPN emissions for a given brake differed by a factor of 2.5 ± 0.5, comparable to data from exhaust SPN ILS measurements. This article provides an overview of lessons learned and subsequent measures incorporated in an upcoming global technical regulation to reduce measurement variability when sampling and measuring brake particle emissions for light-duty vehicles up to 3.5 t.

Comparative Study on the Friction Behaviour and the Particle Formation Process between a Laser Cladded Brake Disc and a Conventional Grey Cast Iron Disc

Brake-wear particle emissions are the result of the components of a friction brake being in tribological contact, and they are classified as non-exhaust emissions. Since most of the emitted particles belong to the size classes of particulate matter (≤10 μm) and differ significantly in terms of their physico-chemical properties from automotive exhaust emissions, this source is of particular relevance to human health and, therefore, the focus of scientific studies. Previous studies have shown that coated brake discs offer significant wear and emission reduction potential. Nevertheless, no studies are available that describe the specific particle formation process, the contact conditions, the structure of the friction layer and the differences compared to conventional grey cast iron discs. The aim of this study is to describe those differences. For this purpose, the tribological behaviour, the structure of the friction layer and the associated particle dynamics within the friction contact between a laser cladding coated disc and a conventional grey cast iron disc are compared. The required investigations are carried out both ex situ (stationary) and in situ (dynamic). Parallel to the tribological investigations, the particle emission behaviour is determined on an inertia dynamometer using a constant volume sampling system (CVS) and equipment for particle number and particle size distribution measurement. The results show that, for two different brake pads, the laser cladding brake disc has lower wear and less particulate emissions than the grey cast iron brake disc. The wear behaviour of the coating varies significantly for the two brake pads. By contrast, the grey cast iron brake disc shows a significantly lower influence.

Brake wear-derived particles: Single-particle mass spectral signatures and real-world emissions

Brake wear is an important but unregulated vehicle-related source of atmospheric particulate matter (PM). The single-particle spectral fingerprints of brake wear particles (BWPs) provide essential information for understanding their formation mechanism and atmospheric contributions. Herein, we obtained the single-particle mass spectra of BWPs by combining a brake dynamometer with an online single particle aerosol mass spectrometer and quantified real-world BWP emissions through a tunnel observation in Tianjin, China. The pure BWPs mainly include three distinct types of particles, namely, Ba-containing particles, mineral particles, and carbon-containing particles, accounting for 44.2%, 43.4%, and 10.3% of the total BWP number concentration, respectively. The diversified mass spectra indicate complex BWP formation pathways, such as mechanical, phase transition, and chemical processes. Notably, the mass spectra of Ba-containing particles are unique, which allows them to serve as an excellent indicator for estimating ambient BWP concentrations. By evaluating this indicator, we find that approximately 4.0% of the PM in the tunnel could be attributable to brake wear; the real-world fleet-average emission factor of 0.28 mg km−1 veh−1 is consistent with the estimation obtained using the receptor model. The results presented herein can be used to inform assessments of the environmental and health impacts of BWPs to formulate effective emissions control policies.