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Influence of iron–aluminum alloy on the tribological performance of non-asbestos brake friction materials – a solution for copper replacement

Saikrishnan G. (Department of Rubber and Plastics Technology, Madras Institute of Technology, Anna University, Chennai, India and Department of Mechanical Engineering, Rajalakshmi Institute of Technology, Chennai, India)
Jayakumari L.S. (Department of Rubber and Plastics Technology, Madras Institute of Technology, Anna University, Chennai, India)
Vijay R. (Department of Production Engineering, National Institute of Technology, Tiruchirappalli, India)
Lenin Singaravelu D. (Department of Production Engineering, National Institute of Technology, Tiruchirappalli, India)

Industrial Lubrication and Tribology

ISSN: 0036-8792

Article publication date: 28 August 2019

Issue publication date: 14 January 2020

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.

Keywords

Acknowledgements

Authors are thankful to Mr Shishir Gupta, Director of Risus Ventures (OPC) Pvt. Ltd. and Indian Distributor of ITAPROCHIM, Italy for providing iron–aluminum alloy samples for research purpose. Authors are also thankful to the well-wisher(s), who have helped in the manufacturing and testing of the composites.

Citation

G., S., L.S., J., R., V. and D., L.S. (2020), "Influence of iron–aluminum alloy on the tribological performance of non-asbestos brake friction materials – a solution for copper replacement", Industrial Lubrication and Tribology, Vol. 72 No. 1, pp. 66-78. https://doi.org/10.1108/ILT-12-2018-0441

Publisher

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Emerald Publishing Limited

Copyright © 2019, Emerald Publishing Limited