Mechanical Properties of Powder Based Steel used as Backing Plate in Heavy Duty Brake Pad Manufacturing

The aims of the present study is to develop a powder based steel used as backing plate for heavy duty brake pad applications. Three powder based back plate steel compositions namely B1 (C- 0.3, Cu – 1.5, P -0.3, Fe – 97.9), B2 (C- 0.1, Cu – 2.5, SiC-1, Fe – 96.4) and B3(C- 0.5, Cu – 2.5, SiC-1, Fe – 96.0) were prepared using a hot powder preform forging technique. The forged samples are of (25× 50×10 mm3) dimensions. These samples were hot rolled and annealed to relieve the residual stresses. These samples were characterized in terms of microstructure, porosity content/densification, hardness and tensile properties. Densification as high near to theoretical density has been realized. Hot powder preform forging using closed die showed better densification. Rolled and annealed microstructure showed lesser porosity content than the forged one. Phosphorous causes hardening of ferrite in solid solution with iron. Compositions B1, showed reasonable elongation and it improved further on annealing. It was observed in this present investigation that, the addition, such as SiC and Cu caused increase in strength. Steel developed in the investigation are used as powder based backing plate in Manufacturing of iron based brake pads used in heavy duty applications.

Development of Iron Based Brake Friction MMC Used for Military Aircraft Application by A New P/M Route

A new P/M route based hot powder pre-form forging process has been evolved to develop high density brake materials for heavy duty applications. Number of iron based MMC’s so developed offer better characteristics for braking applications in comparison to the materials developed through conventional P/M route based on high pressure compaction and pressure sintering. The process so developed in the present investigations is much simpler and easy to adopt by existing P/M industries. Hot powder pre-form forging technique for making heavy duty brake pads offers better opportunity for pore free material with better bonding between various metallic and non-metallic constituents. After conducting an initial characterization such as hardness, density and Pin-on Disc tests, the samples were tested for high energy (32,933kgfm) on Sub-scale dynamometer under Rejected Take Off conditions. The results have also been compared with respect to brake pads employed in heavy duty Military aircraft tested under identical laboratory conditions. The present work indicates that the newly developed materials compare better than the one being currently employed in heavy duty aircraft. The reasons for better performance are improved processing technique and resulting higher levels of density and improved binding of the product.

Development of Iron Based Brake Friction Material by Hot Powder Preform Forging Technique used for Medium to Heavy Duty Applications

A promising friction material, Iron -based friction material, was prepared by powder metallurgy (PM) processing utilizing hot powder preform forging (near net-shape).The preparation of the product and its characterization are presented in this paper. These products are useful in heavy duty Military Aircraft applications such as AN-32. In order to eliminate costly environmental control systems to protect products during their high temperature processing (as is conventionally practiced employing hydrogen gas), the present investigation relies on carbon (mixed in the brake pad formulation) as reducing agent and high temperature oxidation resistant glassy coating (separately developed) applied over the product’s surface after cold compacting. After conducting an initial characterization such as hardness, density and Pin-on Disc tests, the samples were tested in sub-scale dynamometer under Rejected Take Off conditions. It was observed that the obtained density in the present investigation is higher than the reported density obtained by sintering route, and wear is on the lower side of the range as per the Aeronautical Standards. Optical metallography was used to investigate the microstructure of friction, interface and backing layer. It was observed that the distribution of ingredients in matrix was homogeneous. The results also indicate that the coefficient of friction is more stable, and wear is lower with respect to temperature rise. .

Development of Aluminium Based Hybrid Metal Matrix Composites for Heavy Duty Applications

The present study deals with the investigation of dry sliding wear behavior of aluminium alloy based composites, reinforced with silicon carbide particles and solid lubricants such as graphite/antimony tri sulphide (Sb2S3). The first one of the composites (binary) consists of Al. with 20% Silicon Carbide particles (SiCp) only. The other composite has SiCp and solid lubricants: Graphite + Sb2S3 (hybrid composite) at solid state. Both composites are fabricated through P/M route using “Hot powder perform forging technology”. The density and hardness are measured by usual methods. The pin-on-disc dry wear tests to measure the tribological properties are conducted for one hour at different parameters namely load: 30, 50 and 80N and speed: 5, 7 and 9m/s. The tested samples are examined using scanning electron microscope (SEM) for the characterization of microstructure and tribolayer on worn surface of composites. The results reveal that wear rate of hybrid composite is lower than that of binary composite. The wear rate decreased with the increasing load and increased with increasing speed. The results of the proposed composites are compared with iron based metal matrix composites (FM01N, FM02) at corresponding values of test parameters. These iron based metal matrix composites are also fabricated by P/M route using ‘Hot powder perform forging technology’. The comparative study reveals that the proposed composites have lower friction coefficient, less temperature rise and low noise level;however they have little higher wear rate. It is concluded that the hybrid composite has acceptable level of tribological characteristics with blacky and smooth worn surface.

Development and Characterization of Fe-Based Friction Material Made by Hot Powder Preform Forging for Low Duty Applications

This present paper investigates the friction and wear properties of friction material developed by ‘Hot Powder Preform Forging’ technique. The conventional technique to manufacture Metallo-ceramic brake pads was successfully and economically tried to replace the above process. Compacting and sintering technology suffers from certain major limitations such as inadequate joining of friction element with backing plate, poor density levels achieved in friction element owing to limited application of pressure during compacting, poor thermal conductivity due to high levels of porosity in the product, poor strength due to segregation of the impurities along prior particle boundaries (PPB’s) and, wide variations in final characteristics due to large number of variables involved. In contrast to these limitations, the present technique can offer brake pads of much simpler chemistry but with improved performance on account of simultaneous application of pressure and temperature and with better control of variables. Fade and recovery studies were carried out on a Krauss machine tester following the Economic Commission for Europe Regulation for replacement brake linings (ECE R-90). μfade, μrecovery, μperformance, % age fade , % age recovery & temperature rise lie within the range for friction materials used for low duty applications. The mechanical properties of these materials were characterized using ASTM standards.

Effect of Chromium on the Corrosion Behavior of Powder-Processed Fe-0.6 wt % P Alloys

Phosphoric irons (i.e. Fe-P alloys containing low phosphorous in the range 0.1 to 0.7 wt. %) with/without addition of chromium were prepared by powder forging route. The corrosion behaviour of these alloys was studied in different environments. The various environments chosen were acidic (0.25 M H2SO4 solution of pH 0.6), neutral/marine (3.5 % NaCl solution of pH 6.8) and alkaline (0.5 M Na2CO3 + 1.0 M NaHCO3 solution of pH 9.4). The corrosion studies were conducted using Tafel Extrapolation and Linear Polarization techniques. The results were compared with the corrosion resistance of electrolytic Armco iron. It was observed that, chromium improved the resistance to corrosion in marine conditions only. Corrosion rates were higher in acid medium due to the enhanced hydrogen evolution and hence, the cathodic reaction. The corrosion rates were minimal in alkaline medium and low in neutral solution.