Copper-Free Resin-Based Braking Materials:A New Approach for Substituting Copper with Fly-Ash Cenospheres in Composites

Copper particles emitted from braking have become a significant source of environmental pollution.However,copper plays a crucial role in resin-based braking materials.Developing high-performance braking materials without copper has become a significant challenge.In this paper,the resin-based braking materials were filled with flyash cenospheres to develop copper-free braking materials.The effects of fly-ash cenospheres on the physical properties,mechanical and friction and wear properties of braking materials were studied.Furthermore,the wear mechanism of copper-free resin-based braking materials filled with fly-ash cenospheres was discussed.The results indicate that the inclusion of fly-ash cenospheres in the braking materials improved their thermal stability,hardness and impact strength,reduced their density,effectively increased the friction coefficient at medium and high temperatures,and enhanced the heat-fade resistance of the braking materials.The inclusion of fly-ash cenospheres contributed to the formation of surface friction film during the friction process of the braking materials,and facilitated the transition of form from abrasive wear to adhesive wear.At 100-350℃,the friction coefficient of the optimal formulation is in the range of 0.57-0.61,and the wear rate is in the range(0.29-0.65)×10^(-7) cm^(3)·N^(-1)·m^(-1),demonstrating excellent resistance to heat-fade and stability in friction coefficient.This research proposes the use of fly-ash cenospheres as a substitute for environmentally harmful and expensive copper in brake materials,which not only improves the performance of braking materials but also reduces their costs.

Microstructure and frictional properties of 3D needled C/SiC brake materials modified with graphite

The 3D needled C/SiC brake materials modified with graphite were prepared by a combined process of the chemical vapor infiltration,slurry infiltration and liquid silicon infiltration process.The microstructure and frictional properties of the brake materials were investigated.The density and open porosity of the materials as-received were about(2.1±0.1)g/cm3and(5±1)%,respectively.The brake materials were composed of 59%C,39%SiC,and 2%Si(mass fraction).The content of Si in the C/SiC brake materials modified with graphite was far less than that in the C/SiC brake materials without being modified with graphite,and the Si was dispersed.The braking curve of the 3D needled C/SiC modified with graphite was smooth,which can ensure the smooth and comfortable braking.The frictional properties under wet condition of the 3D needled C/SiC modified with graphite showed no fading.And the linear wear rate of the C/SiC modified with graphite was lower than that of the C/SiC unmodified.

Effect of zinc powder content on tribological behaviors of brake friction materials

Brake friction materials with different zinc powder contents(0,2,4,6,8 wt.%)were fabricated via powder metallurgy method.The results indicate that with the increasing zinc powder content,the density and thermal conductivity of the materials gradually increase,while the hardness decreases monotonously.With increasing zinc powder content,the curve of the nominal friction coefficient shows fluctuating trend but the lowest friction coefficient also shows an increase.However,the wear rate and braking noise of the friction material monotonously decrease with increasing zinc content.This effect may be attributed to the transformation of the tribological mechanism from adhesive wear and abrasive wear to adhesive wear.The brake friction material with 4 wt.%zinc powder exhibits both the best tribological and noise performance.

Frictional response of a novel C/C-ZrB_(2)-ZrC-SiC composite under simulated braking

A novel braking material,C/C-ZrB_(2)-ZrC-SiC carbon fibre-reinforced hybrid ceramic matrix composite,was prepared by chemical vapour infiltration and polymeric precursor infiltration and pyrolysis.Investigation of the microstructure of C/C-ZrB_(2)-ZrC-SiC composite showed the homogenous dispersion of three-phase ceramic as the matrix.The frictional properties of the hybrid C/C-ZrB_(2)-ZrC-SiC ceramic matrix composite were measured by a disk-on-disk type dynamometer under dry and wet conditions to simulate the normal landing state of aircraft brake disk friction pairs.C/C-ZrB_(2)-ZrC-SiC ceramic matrix composite has a higher and more stable friction coefficient under wet condition than under dry condition,indicating that the composite has better performance compared with C/C or C/C-SiC braking materials.