Ecological Transition in the Field of Brake Pad Manufacturing: An Overview of the Potential Green Constituents

Laboratory Tests on the Possibility of Using Flax Fibers as a Plant-Origin Reinforcement Component in Composite Friction Materials for Vehicle Braking Systems

Braking systems are extremely important in any vehicle. They convert the kinetic energy of motion into thermal energy that is dissipated into the atmosphere. Different vehicle groups have different nominal and maximum speeds and masses, so the amount of thermal energy that needs to be absorbed by the friction pads and then dissipated can vary significantly. Conventional friction materials are composite materials capable of withstanding high temperatures (in the order of 500-600 °C) and high mechanical loads resulting from braking intensity and vehicle weight. In small vehicles traveling at low speeds, where both the amount of thermal energy and its density are limited, the use of slightly weaker friction materials with better ecological properties can be considered. This work proposes a prototype composite friction material using flax fibers as reinforcement instead of the commonly used aramid. A number of samples were prepared and subjected to laboratory tests. The samples were prepared using components of plant origin, specifically flax fibers. This component acted as reinforcement in the composite friction material, replacing aramid commonly used for this purpose. The main tribological characteristics were determined, such as the values of the coefficients of friction and the coefficients of abrasive wear rate. For this purpose, an authorial method using ball-cratering contact was used. The results were analyzed using statistical methods. It was found that the composite material using flax fibers does not differ significantly in its tribological properties from conventional solutions; so, it can be assumed that it can be used in the vehicle's braking system.

Unrecognized volatile and semi-volatile organic compounds from brake wear

Motor vehicles are among the major sources of pollutants and greenhouse gases in urban areas and a transition to "zero emission vehicles" is underway worldwide. However, emissions associated with brake and tire wear will remain. We show here that previously unrecognized volatile and semi-volatile organic compounds, which have a similarity to biomass burning emissions are emitted during braking. These include greenhouse gases or, these classified as Hazardous Air Pollutants, as well as nitrogen-containing organics, nitrogen oxides and ammonia. The distribution and reactivity of these gaseous emissions are such that they can react in air to form ozone and other secondary pollutants with adverse health and climate consequences. Some of the compounds may prove to be unique markers of brake emissions. At higher temperatures, nucleation and growth of nanoparticles is also observed. Regions with high traffic, which are often disadvantaged communities, as well as commuters can be impacted by these emissions even after combustion-powered vehicles are phased out.

Insights on non-exhaust emissions: An approach for the chemical characterization of debris generated during braking

Up to 50 % of total PM2.5 emissions are due to particles derived from the automotive sector, and both exhaust and non-exhaust emissions contribute to the pollution of urban areas. Fuel incomplete combustion, or lubricant degradation due to high temperatures during the combustion process, are responsible for exhaust emissions. The non-exhaust ones concern brakes, tires and road surface-wear emissions and road resuspension contribution. The present study aims to provide a methodological approach for a detailed chemical characterization of wear friction products by means of a large array of techniques including spectroscopic tools, thermogravimetric analysis (TGA), chromatography, morphological and elemental analysis. The dust sample derived from the wear of a brake pad material was collected after a Noise & Vibration Harshness (NVH) test under loads similar to a Worldwide Light vehicle Test Procedure (WLTP) braking cycle. The TGA shows that only a small fraction is burned during the test in an oxidizing environment, testifying that the sample consists mostly of metals (more than 90 %). Fe exhibits the highest concentrations (50-80 %, even in the form of oxides). Also other kinds of metals, such as Zn, Al, Mg, Si, S, Sn, Mn, occur in small quantities (about 1-2% each). This finding is confirmed by X-ray diffraction (XRD) analysis. The organic fraction of the debris, investigated by means of Raman spectroscopy, has an evident aromatic character, probably due to oxidative phenomena occurring during the braking cycle test. Noteworthy, the extraction of the dust sample with organic solvents, revealed for the first time the presence of ultrafine particles (UFPs), even in the range of few nanometers (nanoparticles), and polycyclic aromatic hydrocarbons (PAHs), recognized as highly toxic compounds. The simultaneous presence of toxic organic carbon and metals makes of concern the non-exhaust emissions and mandatory a deep insight on their structure and detailed composition.

Composites in Vehicles Brake Systems-Selected Issues and Areas of Development

Modern composite materials, thanks to their excellent properties, are widely used [...].

Study of the Influence of the Copper Component's Shape on the Properties of the Friction Material Used in Brakes-Part One, Tribological Properties

Brakes play an extremely important role in any vehicle. In today's automotive industry, friction brakes are most often used, in which the composite material of the brake pad cooperates with a cast iron disc. While little can be modified in the case of discs, in the case of pads, the composition of the material used for its production can have an almost unlimited number of possibilities. Both scientists and manufacturers invent and test new combinations to achieve the desired end result. A similar task was undertaken in this work. Bearing in mind the fact that materials commonly used as reinforcing materials generate undesirable threats in the production process, it was decided to check whether this role could be taken over by another substance that is already present in brake pads; this substance is copper. A number of samples containing copper, in the form of powder and fibers, were made, and then the samples were subjected to tribological tests in order to determine the coefficient of friction and abrasive wear rate. The ball-cratering research method was used, and the Taguchi process optimization method was used to plan the experiment. As a result of the tests, it was found that the replacement of aramid fibers with copper fibers does not significantly affect the value of COF and the abrasive wear rate.

Process Optimization of Automotive Brake Material in Dry Sliding Using Taguchi and ANOVA Techniques for Wear Control

In this paper, an investigation of the load-dependent wear behavior of copper-free semi-metallic brake material is presented. The experiments were conducted in ambient thermal settings with varying sliding velocities (3.141 m/s, 2.09 m/s, and 1.047 m/s), normal load (60 N, 50 N, and 40 N), and sliding distance (4500 m, 3000 m, and 1500 m). Taguchi’s method was used in designing experiments to examine the output through an L9 orthogonal array. ANOVA was used to identify the consequence of interactions among different constraints. It also established the significant contribution of each process factor. The objective was set as the ‘smaller is better’ criterion to find minimum wear conditions. The impact of the normal load on the wear process was found to be maximum (71.02%), followed by sliding velocity (27.84%) and sliding distance (1.14%). The optimum condition for the minimum wear rate was found at 40 N normal load, 1500 m sliding distance, and 3.14 m/s sliding velocity. The results were confirmed with validatory friction experiment runs. The resulting error was within 10% error, which verified the experiment methods. The SEM investigation of worn surfaces of pin and disc confirmed abrasive wear and adhesive wear at 60 N and 40 N, respectively.