Tribological and Emission Behavior of Novel Friction Materials

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.

A novel path towards limiting non-exhaust particulate matter emissions of a commercial friction material through the addition of metallurgical slag

Keeping recycling and the circular economy in mind, this study explores the reduction in emission of a highly optimized, commercially employed friction material formulation through the addition of metallurgical slags from a basic oxygen furnace in varying quantities from 6 to 38 wt%. The various compositions were paired with a pearlitic grey cast iron counterface and tested on a pin on disc tribometer. The friction coefficient and pin wear increased with the slag addition but were still within the permissible limit when compared to the original formulation. Specimens with higher slag content observed extremely compacted and extended secondary contact plateaus, which also recorded significant slag presence. The extended plateaus detached in the form of chunks from the mating surfaces, which settled on the equipment hardware and restricted the production of airborne particles. From an industrial symbiosis perspective, the addition of metallurgical slags proved to be a promising way of obtaining green friction materials with reduced emissions.

A novel study on the reduction of non-exhaust particulate matter emissions through system vibration control

The need to reduce non-exhaust particulate matter emissions is of paramount importance as they pose repercussions on human lives and the environment. In this study, a novel way to limit emissions is proposed based on the minimization of the vibration of the mating bodies. Two model friction material formulations were tested in the form of pins and paired with a pearlitic grey cast iron disc counterface in a laboratory pin on disc apparatus. To reduce the vibrations, a damping tape was wrapped around the pins. With the damping of vibration, a significant drop in the emissions was recorded, and this was correlated with the friction layer establishment during sliding, which observed low disruption. It is believed that the use of this method for reducing emissions can accompany the optimization phase of the brake squeal noise of friction materials, thereby, providing new design perspectives.

Dry Sliding Behavior and Particulate Emissions of a SiC-graphite Composite Friction Material Paired with HVOF-Coated Counterface

Dry sliding wear tests and corresponding particulate matter (PM) analysis were conducted on a newly developed SiC-graphite-based composite friction material, paired with two types of HVOF counterface/discs: WC-CoCr and WC-FeCrAlY coatings, with a conventional martensitic stainless steel counterface as a reference. The trials were conducted on a pin-on-disc testing equipment at room temperature and a constant sliding velocity and contact pressure of 7 m/s and 0.5 MPa, respectively. The coefficient of friction (CoF) curves with the uncoated disc exhibited considerable fluctuations. On the other hand, the coated discs featured an increase in the CoF at the beginning of the tests, followed by either a continuous reduction until the end of the testing duration or the attainment of a steady state regime. The pin wear and emissions with both coatings were appreciably lower when compared to the trials with the uncoated disc. The evaluation of the friction layer observed a significant contribution of the counterface for all the pairings. The PM analysis was conducted on the particles that were lying in the range of 10 μm and 2.5 μm on a scanning electron microscope (SEM), and particles from 2.5 μm and 1 μm on transmission electron microscope (TEM), with an emphasis on the particles that were detached from the pin surface and friction layer to explain the wear mechanisms for each pairing. Through this, the need for the proper selection of both friction material and counterface to avoid the emission of harmful compounds in the environment was highlighted.

Input Parameters for Airborne Brake Wear Emission Simulations: A Comprehensive Review

Non-exhaust emissions, generated by the wear of brake systems, tires, roads, clutches, and road resuspension, are responsible for a large part of airborne pollutants in urban areas. Brake wear accounts for 55% of non-exhaust emissions and significantly contributes to urban health diseases related to air pollution. A major part of the studies reported in the scientific literature are focused on experimental methods to sample and characterize brake wear particles in a reliable, representative, and repeatable way. In this framework, simulation is an important tool, which makes it possible to give interpretations of the experimental results, formulate new testing approaches, and predict the emission produced by brakes. The present comprehensive literature review aims to introduce the state of the art of the research on the different aspects of airborne wear debris resulting from brake systems which can be used as inputs in future simulation models. In this review, previous studies focusing on airborne emissions produced by brake systems are investigated in three main categories: the subsystem level, system level, and environmental level. As well as all the information provided in the literature, the simulation methodologies are also investigated at all levels. It can be concluded from the present review study that various factors, such as the uncertainty and repeatability of the brake wear experiments, distinguish the results of the subsystem and system levels. This gap should be taken into account in the development of future experimental and simulation methods for the investigation of airborne brake wear emissions.