Development and Characterization of Copper Free Friction Composites for Automotive Brake Applications

Abstract

Brake friction materials are crucial in automobiles for reducing speed and stopping newlinevehicles. A brake is a mechanical component that converts kinetic energy into heat via newlinefriction. A substantial amount of heat is generated at the braking interface when braking. newlineThe various components in brake friction composites must withstand these temperatures newlinewithout losing their properties. The main goal of these composites is to provide excellent newlinefade and wear resistance. Recent advancements in friction materials ensure effective newlinebraking performance while maximizing safety and comfort. Synthetic and natural products newlinehave been identified as superior alternatives to banned toxic materials like asbestos and newlinecopper. Thus, global research focuses on improving brake friction composites by newlineoptimizing their ingredients. Despite numerous studies on various ingredients, few have newlineexamined the commonly used ones in friction material formulations. Even minor changes newlinein composition and structure can significantly impact brake friction material performance. newlineThis study explores the critical areas concerning fillers and friction modifiers aimed at newlinereplacing asbestos and copper by developing brake pads and brake liners with varied newlineingredients and examining their effects. It includes the combined impact of Expanded newlineGraphite and Mica, exploring the use of Lignin and various Micaceous Mineral Additives, newlinecomparing different abrasives, and assessing the influence of mixing parameters, newlineparticularly timing variation, on the frictional performance of brake friction composites. newlineThis research aims to develop brake friction materials using expanded graphite and mica newlineflakes, produced into six standard brake pads of varying proportions. These materials were newlinecharacterized physically, chemically, and mechanically per IS 2742 and ISO 6312 newlinestandards. Tribological properties, including fade and recovery, were assessed using a fullscale newlineinertia brake dynamometer as per JASO-C-406 standards. Worn surface analysis was newlineconducted using a scanning electron