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Article
Publication date: 27 July 2022

Saikrishnan G., Jayakumari L.S. and Vijay R.

The purpose of this paper is to deal with the tribological study on the brake pads developed using various purity-based graphitized graphite.

158

Abstract

Purpose

The purpose of this paper is to deal with the tribological study on the brake pads developed using various purity-based graphitized graphite.

Design/methodology/approach

This paper deals with developing copper-free brake pads by using graphite as a key lubricant produced using a graphitization process with purity percentages (85, 90 and 95%). The brake pads were developed using traditional manufacturing processes and evaluated for their physical, chemical, thermal and mechanical properties as per industrial standards. Fade and recovery characteristics were analyzed using a full-scale inertia brake dynamometer as per JASO-C-406. The scanning electron microscope was used to analyze the worn surfaces of the brake pads.

Findings

The testing findings reveal that the brake pads with 95% graphitized graphite showed better shear strength with good adhesion levels and lesser density, hardness, acetone extract value, loss on ignition and higher porosity. Effectiveness studies of brake pads with graphite (95% graphitized) showed better results at higher pressure speed conditions than others because of better plateau formation and adequate lubrication.

Originality/value

This paper discusses graphitized graphite of different purity influences brake pad's tribological performance by modifying tribo-films and reducing friction undulations.

Details

Industrial Lubrication and Tribology, vol. 74 no. 7
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 28 August 2019

Saikrishnan G., Jayakumari L.S., Vijay R. and Lenin Singaravelu D.

The purpose of this study is to investigate the influence of commercially available iron–aluminum alloy compared to copper, iron and aluminum powders on the tribological…

468

Abstract

Purpose

The purpose of this study is to investigate the influence of commercially available iron–aluminum alloy compared to copper, iron and aluminum powders on the tribological performances of friction composites. The main objective is to replace copper from the friction composite formulations.

Design/methodology/approach

In this study, friction composites were fabricated as of standard brake pads using commercially available iron–aluminum alloy and compared to copper powder, iron powder and aluminum powder-based without varying the other ingredients. The brake pads were developed as per the industrial procedure. The physical, mechanical and thermal properties of the developed brake pads were analyzed as per industrial standards. Tribological properties were analyzed using the chase test. Initial speed and deceleration tests in a real-time braking scenario were performed using a full-scale inertia brake dynamometer. Worn surface analysis was done using a scanning electron microscope.

Findings

The results indicate that iron–aluminum alloy (mechanomade)-based friction composites possess good physical, chemical, thermal and mechanical properties with stable fade and recovery characteristics due to its composition and flake morphology. During initial speed and deceleration braking conditions, iron–aluminum alloy also showed good tribological behavior.

Originality/value

This paper explains the influence of commercially available iron–aluminum alloy in friction composites in enhancing tribological performance by its composition and flake morphology, which could potentially replace copper in friction composites by solving subsequent problems.

Details

Industrial Lubrication and Tribology, vol. 72 no. 1
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 2 July 2020

Dinesh Shinde, Mukesh Bulsara and K.N. Mistry

The purpose of this paper is to evaluate experimentally the influence of different surface roughness of the contacting disc on tribological performance of the non-asbestos brake…

190

Abstract

Purpose

The purpose of this paper is to evaluate experimentally the influence of different surface roughness of the contacting disc on tribological performance of the non-asbestos brake friction material (BFM).

Design/methodology/approach

Taguchi method was applied to design an experiment using three different discs of gray cast iron with different surface roughness, which is measured using optical profilometer. These discs were subjected to sliding against pins prepared with the developed non-asbestos BFM, using pin on disc friction and wear monitor.

Findings

The experimental results shows that the disc 2 (Ra = 3.77 µm) gives wear of 22.78 µm and coefficient of friction of 0.462, which is recommended for extreme brake performance. Analysis of Taguchi design revealed that the disc surface was most significant parameter among the parameters under study.

Practical implications

During braking, continuous sliding between the BFM and brake disc or drum not only results into wear of BFM but also changes the surface finish of the brake drum or disc. This leads to variation in surface topography of the drum or disc surface with application of brakes, which further affects the characteristics of the BFM.

Originality/value

The tribological performance of BFM depends upon the topography of the surface on which it was sliding. To get best performance of the non-asbestos friction materials, disc having moderate surface finish is recommended. Scanning electron microscope micrographs had shown the different plateaus formed and energy-dispersive X-ray spectroscopy spectra identified presence of different chemical elements prior to sliding of the pins surface over different discs surface topography.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2020-0120/

Details

Industrial Lubrication and Tribology, vol. 72 no. 10
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 2 November 2020

Sathickbasha K., Selvakumar A.S., Surya Rajan Balachandran and Hariharasakthisudhan P.

The purpose of this study is the influence of various combinations of metal sulfides on the tribological performance of brake pads.

233

Abstract

Purpose

The purpose of this study is the influence of various combinations of metal sulfides on the tribological performance of brake pads.

Design/methodology/approach

Three brake pads were prepared using the possible combination of any two of the solid lubricants from Bismuth trisulfide (Bi2S3); Tin disulfide (SnS2) and Antimony trisulfide (Sb2S3) are chosen and blended with molybdenum disulfide and graphite. The tribological performance was compared with the brake pad containing aftermarket sulfide mixture. The tribological performance parameters such as performance coefficient of friction, fade percent, recovery percent, wear thickness loss, time is taken to reach the maximum temperature and fluctuation of friction were investigated using Chase tribometer adopting IS 2742 Part-4 (1994) test procedure.

Findings

The friction stability of the brake pad with 4Wt% of MoS2, Bi2S3 and SnS2 was observed to be better, but it showed poor wear performance and aggressive towards the rotor, whereas the brake pad contained 4Wt% of MoS2, Bi2S3 and Sb2S3 exhibited improved wear performance.

Originality/value

This paper explains the influence of the combination of multiple metal sulfide in the tribological performance of the copper-free brake friction composite.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2020-0249/

Details

Industrial Lubrication and Tribology, vol. 73 no. 2
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 28 February 2023

Kanagaraj M., Babu S., Sudhan Raj Jegan Mohan and Christy T.V.

This study aims to compare the friction and wear performance of commercial brake pads for four wheelers among metallic, semimetallic and non-asbestos organic (NAO) formulations to…

191

Abstract

Purpose

This study aims to compare the friction and wear performance of commercial brake pads for four wheelers among metallic, semimetallic and non-asbestos organic (NAO) formulations to identify one with the right combination of properties for optimal performance.

Design/methodology/approach

Three commercially available brake pads for four-wheeler automotive applications were acquired. Samples were cut from the brake pads to study their physical and mechanical properties. The effects of friction and wear were analyzed using a pin-on-disk tribotester. Surface morphology on the worn-out surface of the brake pads was studied.

Findings

It was observed that the frictional properties remained stable and less fluctuating in the semimetallic and NAO pads, whereas the coefficient of friction of all the pads varied between 0.35 and 0.55. The wear rate of the metallic pads is less than that of NAO and semimetallic pads. The surface morphology studies revealed that the metallic pads contained more primary plateaus and smaller amounts of secondary plateaus compared to semimetallic and NAO pads, resulting in better wear resistance characteristics.

Originality/value

Because the market is flooded with various options for brake pad materials, it is imperative that the vehicle manufacturers choose the right pad material with great care not only to ensure the optimal functioning of the braking system but also passenger safety. Mechanical and tribological properties of brake pads contribute greatly to their effectiveness. There is a requirement to choose the proper material for a certain application that has a consistent friction coefficient and reduced wear.

Details

Industrial Lubrication and Tribology, vol. 75 no. 3
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 7 May 2021

Mohd Fadzli Bin Abdollah, Hilmi Amiruddin and Mohamad Jabbar Nordin

This study aims to scrutinise the impact of fibre length and its composition on the tribological attributes of oil palm fibre (OPF) polymeric composite as an alternative brake…

208

Abstract

Purpose

This study aims to scrutinise the impact of fibre length and its composition on the tribological attributes of oil palm fibre (OPF) polymeric composite as an alternative brake friction material.

Design/methodology/approach

Fabrication of the sample was conducted by using a hot-compression method. The tribological test was carried out by deploying a ball-on-disk tribometer. Analysis of the data was then done by using the Taguchi approach as well as analysis of variance.

Findings

The results indicated that all design variables (fibre composition, length and treatment) are not statistically significant, as all p-values are greater than 0.05. Remarkably, irrespective of the fibre treatment, the wear rate and coefficient of friction (COF) distribution suggested that a smaller fibre length with a high fibre composition might enhance the composite’s tribological performance with COF of 0.4 and wear rate below than 1 × 10–9 mm3/Nm. The predominant wear mechanisms were identified as micro-cracks, fine grooves and fibre debonding.

Research limitations/implications

In this study, all-inclusive scrutiny needs to be carried out for further exploration.

Originality/value

The main contribution and novelty of this study are opening a new perspective on the formulation of new substances from bio-based material (i.e. OPF) that possess superior tribological characteristics for friction-based applications.

Details

Industrial Lubrication and Tribology, vol. 73 no. 4
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 30 June 2022

Kanagaraj M., Babu S., Sudhan Raj, Jonah N., Gusztáv Fekete and Christy T.V.

The main purpose of this study in the field of automotive brake friction material is to find an effective material to replace the environmentally hazardous copper in the brake pad…

142

Abstract

Purpose

The main purpose of this study in the field of automotive brake friction material is to find an effective material to replace the environmentally hazardous copper in the brake pad formulation.

Design/methodology/approach

Cu is used as functional filler in various forms in the friction material formulation. Because of its hazardous impact to the aquatic life, a suitable replacement of Cu is the main focus of this research. Three novel friction composite materials using ground granulated blast furnace slag (GGBFS) as a suitable alternative for Cu were developed by increasing its Wt.% from 5% to 15% in the step of 5%.

Findings

The physical, mechanical and chemical properties of the developed friction composites were tested as per the industrial standards. The tribological properties were analyzed as per SAE J661 standard using the chase test rig. Initial studies revealed that the friction composite having 5% GGBFS exhibited better physical, mechanical and chemical properties with excellent frictional performance having minimal fluctuations even at higher temperatures. Nonetheless, the results showed that the friction composite containing 15 Wt.% GGBFS revealed a better wear resistance property compared with the other two composites due to the tribo lubricating layer formation at the frictional interface. Scanning electron microscope analysis was performed to understand the wear mechanism and tribo layer formations through topography studies.

Originality/value

This paper explains the influence of GGBFS as a replacement of barytes in brake pads formulation to enhance the tribological performance.

Details

Industrial Lubrication and Tribology, vol. 74 no. 7
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 10 August 2021

Baskara Sethupathi P. and Chandradass J.

This study aims to compare the influence of different solid lubricants on the friction stability of a non-asbestos disc brake pad.

181

Abstract

Purpose

This study aims to compare the influence of different solid lubricants on the friction stability of a non-asbestos disc brake pad.

Design/methodology/approach

Three brake pads were developed using three lubricants, namely, non-asbestos brake pad with sulfide mix (NASM), non-asbestos brake pad with bismuth sulfide (NABS) and non-asbestos brake pad with molybdenum disulfide (NAMO). Sulfide mix was indigenously developed by physically mixing friction modifiers, alkaline earth chemicals and various metallic sulfides homogeneously dispersed in graphite medium. The physical, chemical, mechanical and thermal properties of brake pads were characterized as per industrial standards. The tribological performances were studied using the Chase testing machine as SAE-J661-2012. The worn surface of the pads was studied using scanning electron microscope to analyze the dominating wear mechanism.

Findings

NASM was excellent in fade as well as wear resistance. NABS was better from a wear point of view, but fade resistance was moderate despite its higher cost. NAMO fared average in fade and wear despite its excellent dry lubricating properties. NASM was excellent in terms of fade as well as wear resistance.

Originality/value

Among the selected metal sulfides, the indigenously developed sulfide mix was better than the other two sulfides, which indicates that the synergetic effect of metal sulfides was always preferable to the individual sulfides.

Details

Industrial Lubrication and Tribology, vol. 73 no. 6
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 27 June 2022

Hicri Yavuz and Hüseyin Bayrakceken

The purpose of this paper, brake friction material samples with six different contents were produced using three different fiber types consisting of variable proportions of…

220

Abstract

Purpose

The purpose of this paper, brake friction material samples with six different contents were produced using three different fiber types consisting of variable proportions of huntite mineral and basalt, glass and steel fibers. The friction properties and formation of the transfer film in these friction materials were investigated.

Design/methodology/approach

Friction materials were produced using a hot molding method from materials containing 10%–15% huntite in varying proportions, consisting of basalt, glass and steel fibers. The densities and hardness values of the samples were measured. Friction tests were performed using a brake pad friction material tester to determine tribological properties. After the friction tests, microscopic examination of the sample surfaces was performed using scanning electron microscope (SEM) and three-dimensional (3D) surface profilometer devices.

Findings

Huntite mineral content and fiber type affected the friction coefficient. With an increase in the amount of huntite, the friction coefficient increased in the friction material samples formed with glass and steel fibers. The fiber type and amount of huntite also affected the transfer film formation. The surface roughness values of all the friction materials decreased with an increase in the amount of huntite. The surface roughness values of the samples with glass fibers were higher than those of other samples.

Originality/value

The importance of using huntite minerals and different fiber types in automotive brake friction materials is emphasized. This will help industrial companies and academics study the tribological properties of friction materials.

Details

Industrial Lubrication and Tribology, vol. 74 no. 7
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 23 September 2020

Sundarrajan D., Pitchipoo Pandian and Manoharan Sembian

This paper aims to deal with the synergistic effect of steel slag-molybdenum disulfide particles on fade-recovery performances of non-asbestos organic friction material.

207

Abstract

Purpose

This paper aims to deal with the synergistic effect of steel slag-molybdenum disulfide particles on fade-recovery performances of non-asbestos organic friction material.

Design/methodology/approach

The brake friction materials were developed by using steel slag and molybdenum disulfide particles as individual and combination in the formulation. The brake friction materials were developed in the form of standard brake pads as per the industrial practice. The physical, mechanical and thermal properties of the developed brake pads were tested as per the industrial standards. The tribological properties were analyzed using the Chase test as per IS2742-Part-4. Worn surface analysis was done using a scanning electron microscope.

Findings

The experimental results indicate that the brake pads filled with a combination of steel slag and molybdenum disulfide showed stable friction and less wear rate due to the synergetic nature of abrasive and lubricant.

Originality/value

This paper explains the influence of steel slag and molybdenum disulfide particles as individual and combined in brake pads formulation to enhance the tribological performance by producing stabilized friction with undulations.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2020-0216/

Details

Industrial Lubrication and Tribology, vol. 73 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

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