Sathyamoorthy G., Vijay R. and Lenin Singaravelu D.
This study aims to discuss the impact of using bio-polymer (kraft lignin) in the formulation of passenger vehicle disc brake pads (as a substitute for cashew nutshell liquid…
Abstract
Purpose
This study aims to discuss the impact of using bio-polymer (kraft lignin) in the formulation of passenger vehicle disc brake pads (as a substitute for cashew nutshell liquid [CNSL]-based friction dust) and investigate the characteristics of the pads.
Design/methodology/approach
Within the scope of this investigation, three different brake pads were generated by altering the biopolymer-lignin content in conjunction with the friction dust from CNSL without modifying the other components. The brake pads were created in accordance with industry-standard practices. Industrial standards were used to evaluate the newly created brake pad’s thermal, physical and mechanical qualities. The tribological properties of the materials were determined using a full-scale inertia brake dynamometer. The scanning electron microscope examined the worn surfaces in conjunction with elemental mapping.
Findings
The test findings suggest that the brake pads filled with biopolymer-lignin and CNSL-based friction dust (as a partial replacement 50%) exhibited excellent thermal, physical, mechanical characteristics, as well as steady friction and low wear rate.
Originality/value
A bio-polymer (kraft lignin) in friction composites has the potential to produce eco-friendly brake pads and improve the tribological performance of its copper free-composition, which might be used to replace CNSL-based friction dust in friction composites by addressing the issues raised in this work.
Details
Keywords
Vijay R., Manoharan S. and Lenin Singaravelu D.
This paper aims to deal with the effect of natural barytes purity levels on the tribological performance of brake pads.
Abstract
Purpose
This paper aims to deal with the effect of natural barytes purity levels on the tribological performance of brake pads.
Design/methodology/approach
In this study, brake pads were developed by varying three different natural barytes without varying other ingredients. The brake pads were developed as per the standard 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 a full-scale inertia brake dynamometer. Worn surface analysis was done using scanning electron microscope coupled with elemental mapping.
Findings
The experimental results indicate that the brake pads filled with natural barytes 95% purity had good physical, chemical and mechanical properties with stable friction and less wear rate due to reduced impurity level preventing frictional undulations.
Originality/value
This paper explains the effect of the purity level of natural barytes in brake pads formulation to enhance the tribological performance by altering tribofilms and preventing friction undulations.
Details
Keywords
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…
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
Keywords
Justin Antonyraj I., Vijay R. and Lenin Singaravelu D.
The purpose of this study is to investigate the influence of solid lubricants (tungsten disulfide [WS2]/ Tin disulfide [SnS2]) on the tribological performance of brake pads.
Abstract
Purpose
The purpose of this study is to investigate the influence of solid lubricants (tungsten disulfide [WS2]/ Tin disulfide [SnS2]) on the tribological performance of brake pads.
Design/methodology/approach
In this study, the brake pads were developed by varying the solid lubricants (WS2/SnS2) without varying the other ingredients. The brake pads were developed as per the industrial procedure. Thermal stability was found for varying ingredients and developed pads. The physical, mechanical and thermal properties of the developed brake pads were analyzed as per the industrial standards. The tribological properties were analyzed using the Chase test. The worn surface analysis was done using scanning electron microscopy, elemental mapping and three-dimensional profile analysis.
Findings
The experimental results indicate that the WS2-based brake pads possess good physical, chemical and mechanical properties with stable friction and less wear rate due to its good lubrication film formation and thermal stability natures of WS2.
Originality/value
This paper explains the effect of solid lubricants in brake pads for enhancing the tribological performance by the shearing of crystal structure, thermal stability and tribo film properties of the lubricants.
Details
Keywords
Justin Antonyraj I., Vijay R., Sathyamoorthy G. and Lenin Singaravelu D.
This paper aims to discuss the influence of graphite with varying purity on the tribological performance of brake pads.
Abstract
Purpose
This paper aims to discuss the influence of graphite with varying purity on the tribological performance of brake pads.
Design/methodology/approach
Three distinct brake pads were created within the scope of this experiment by varying the graphite purity without affecting the other components. The brake pads were made using a traditional manufacturing procedure, and industry standards were used to test the chemical, physical and mechanical properties of the newly produced brake pad. A full-scale inertia brake dynamometer was used to determine the material’s tribological characteristics. The worn surfaces of the brake pads were examined using a scanning electron microscope.
Findings
The test results indicate that brake pads containing 99% pure graphite (artificial grade) displayed good physical, chemical and mechanical features, such as consistent friction and a reduced rate of wear because of the lower impurity level, which eliminates frictional undulations.
Originality/value
This paper discusses the influence of graphite purity on the tribological performance of brake pads by modifying tribofilms and reducing friction undulations.
Details
Keywords
Vijay R., Manoharan S., Nagarajan S. and Lenin Singaravelu D.
The purpose of this study is to deals with the effect of premixed dual metal sulfides (tin disulfide + iron disulfide) as a replacement for antimony trisulfide on the tribological…
Abstract
Purpose
The purpose of this study is to deals with the effect of premixed dual metal sulfides (tin disulfide + iron disulfide) as a replacement for antimony trisulfide on the tribological performance of brake friction materials.
Design/methodology/approach
In this study, brake friction materials were developed by using premixed dual metal sulfides as a replacement for antimony trisulfide in the formulation. The brake friction materials were developed in the form of standard brake pads as per the industrial practice. Thermal stability was measured for varying ingredients and developed brake pads using thermogravimetric analysis. 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 SAE J661. Worn surface analysis was done using a scanning electron microscope.
Findings
The experimental results indicate that the brake pads filled with premixed dual metal sulfides had good thermal stability, physical, chemical and mechanical properties with stable friction and less wear rate due to better lubrication preventing friction undulations.
Originality/value
This paper explains the influence of premixed dual metal sulfides as a replacement for antimony trisulfide in brake pads formulation to enhance the tribological performance by preventing friction undulations.
Peer review
The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2020-0144/
Details
Keywords
Manoharan S., Vijay R., Lenin Singaravelu D. and Mohamed Kchaou
The purpose of this work is to investigate the effect of oxide-coated steel in comparison with mild steel fibers on the tribological and corrosion performances of friction…
Abstract
Purpose
The purpose of this work is to investigate the effect of oxide-coated steel in comparison with mild steel fibers on the tribological and corrosion performances of friction composites.
Design/methodology/approach
In this study, the friction composites were developed in the form of standard brake pads by using oxide-coated steel and compared with mild steel fibers-based one without varying the other ingredients. The brake pads were developed as per the industrial procedure. The physical, mechanical, thermal properties of the developed brake pads were analyzed as per the industrial standards. The tribological properties were analyzed using the Chase test. The worn surface analysis was done using scanning electron microscope. Corrosion behavior was also analyzed in both salt and normal water conditions.
Findings
The experimental results indicate that the oxide-coated steel-based friction composites brake pads possess good physical, chemical, thermal, corrosion resistance and mechanical properties with stable fade and recovery characteristics because of its oxide coating and flake morphology.
Originality/value
This paper explains the influence of oxide-coated steel in friction composites for enhancing the tribological performance and corrosion resistance by its oxide coating and flake morphology which could potentially replace mild steel fibers-based problems in friction composites.
Details
Keywords
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.
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
Keywords
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.
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
Keywords
Jin Oh Chung, Sang Ryul Go, Hee Bum Choi and Tae Kwan Son
This paper aims to investigate the temperature dependence of transfer film formation and friction coefficients in NAO friction materials with four different abrasive components…
Abstract
Purpose
This paper aims to investigate the temperature dependence of transfer film formation and friction coefficients in NAO friction materials with four different abrasive components, ZrO2, ZrSiO4, Al2O3 and Fe3O4.
Design/methodology/approach
8.5% SnS2 was added as a lubricating component to friction materials. Friction tests comprised 100 times of consecutive braking application for each friction material under constant temperature of 300°C, 400°C, 500°C and 600°C. After the friction tests, the friction surfaces of the counterpart disks were examined by scanning electron microscope to access the formation of transfer film.
Findings
Coefficients of friction depended on not only friction temperature but also friction history which is related to development of transfer film. The effect of the transfer film formation was to reduce the friction coefficients for most friction materials. Quantities of the transfer film formation varied with friction materials; at low temperature below 400° the transfer film formation was most active in the Fe3O4 materials, while at 600° it was the most active in the Al2O3 material. The effect of the lubricating component SnS2 was to suppress the formation of transfer film, thus enhancing friction coefficients.
Social implications
The enhancement of friction coefficients with addition of small amount of lubricating components such as SnS2 is expected to open a new approach in developing high performance-brake pads.
Originality/value
Temperature was the controlling parameter in the present test. Under these test modes, transfer film could be fully developed to access the role of the transfer film.
Peer review
The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2019-0427/