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.

Microstructures and compressive properties of AZ91D/fly-ash cenospheres composites

Novel AZ91D Mg alloy/fly-ash cenospheres(AZ91D/FACs)composites were fabricated by melt stir technique.Fly-ash cenosphere particles with 4%,6%,8%,10%in mass fraction and 100μm in size were used.Hardness and compressive strength of the composites were measured.The effects of mass fraction of cenospheres on the microstructure and compressive properties were characterized.The results show that the cenospheres are uniformly distributed in the matrix and there is no sign of cenosphere cluster or residual pore.The densities of the composites are 1.85-1.92 g/cm 3 .By comparing with matrix,the compressive yield strength of the composites is improved,and the cenospheres is filled with Mg matrix alloy.SEM,XRD and EDX results of the composites show clear evidence of reaction product at cenosphere/matrix interface.On the basis of XRD and EDX,composition, structure and thermodynamic analysis,the main interfacial phase between the cenosphere and AZ91D Mg alloy was identified to be MgAl2O4.

Damping properties and mechanism of aluminum matrix composites reinforced with glass cenospheres

The damping properties were improved by preparing Al matrix composites reinforced with glass cenospheres through the pressure infiltration method.Transmission electron microscopy and scanning electron microscopy were employed to characterize the microstructure of the composites.The low-frequency damping properties were examined by using a dynamic mechanical thermal analyzer,aiming at exploring the changing trend of damping capacity with strain,temperature,and frequency.The findings demonstrated that the damping value rose as temperature and strain increased,with a maximum value of 0.15.Additionally,the damping value decreased when the frequency increased.Dislocation damping under strain and interfacial damping under temperature served as the two primary damping mechanisms.The increase in the density of dislocation strong pinning points following heat treatment reduced the damping value,which was attributed to the heat treatment enhancement of the interfacial bonding force of the composites.

Structure and Properties of BaFe_(12)O_(19) Coated Fly Ash Cenospheres by Sol-Gel Process

Thin films of barium hexaferrite were prepared on fly ash cenosphere particles by the sol-gel method using Fe（ NO3 ）3 ·9H2O, Ba（ NO3 ）2 and citric acid as raw materials. The prepared films were characterized by differential thermal and thermogravimetric analysis （DTA-TG）, X-ray diffraction analysis （XRD）, scanning electron microscopy （SEM）, energy dispersive spectroscopy （EDX）, X-ray photoelectron spectroscopy （XPS）, and vibrating sample magnetometry . The magnetic and structural properties of barium hexaferrite coated cenosphere particles were also studied. The experimental results show that even and continual barium hexaferrite coatings were prepared on fly ash cenospheres , and the magnetic conductivity was imparted to these non-conducting oxide ceramic particles. The low density barium hexaferrite coated cenosphere particles may be atilized for manufacturing microwave absorbing materials.

Hollow Cancrinite Zeolite Spheres in situ Transformed from Fly Ash Cenosphere

A novel hollow microsphere structure with cancrinite zeolite grown from the shell of fly ash cenosphere has been successfully prepared through in situ transformation in vapor phase; the orientation and morphology of cancrinite can be greatly improved by adding tetrapropylammonium hydrate into the synthetic system.

Analysis of Mechanical Characteristics of Fly Ash Cenospheres Reinforced Epoxy Composites

Fly ash cenospheres（FACs） as a recycling material of industrial waste has become a competitor for other inorganic particle fillers. Epoxy resin（EP） composites reinforced with different content of FACs as well as different size grading ratio were prepared. The surface modification of FACs particles was conducted before incorporating into EP matrix. The impact and flexural strengths and the flexural modulus were investigated, and the fracture surfaces of the testing samples were analyzed using SEM. Results showed that FACs had an obvious effect on the mechanical characteristics of the FACs/EP composites. With increasing weight fraction of FACs, the impact and flexural strengths and the flexural modulus of EP composite samples increased, and reached the highest values when the weight fraction of FACs reached 15 wt%. The mechanical characteristics of the FACs/EP composites however deteriorated with further increasing of FACs content. For the EP composites reinforced with different size grading ratio of FACs, the larger proportion of small FACs particles, the better mechanical properties of the EP composites. The results were analyzed from the aspect of the plastic deformation, new surface formation and fracture absorption energy. The synergistic effect of the size grading ratio of FACs was not obvious, which would be further investigated.

Effect of cenospheres addition on microstructure and properties of AZ91D alloy

The cenospheres/AZ91D composites were fabricated by melt stir method. The phases, microstructure and tensile fracture morphology of the composites were analyzed using XRD, Olympus metallurgical microscopy and SEM methods. The thermal expansion coefficient(CTE) and tensile properties were measured. The results showed that the cenospheres distribute uniformly in the Mg alloy matrix and refine the matrix microstructure. Mg2 Si and MgO were found in addition to α-Mg and β-Mg17Al12 phases using XRD. The CTE of the composites reduced after the cenospheres are added. The yield strength of the composites increases significantly with an increase in the mass fraction and a decrease in the size of the cenospheres. The tensile strength of the composites achieves maximum when the mass fraction of cenospheres is 9wt.% and the size of cenospheres is 80 μm. The fracture mechanism of the composites is cleavage fracture.

Corrosion Behavior of Cenosphere Reinforced Al7075 Metal Matrix Composite —An Experimental Approach

Aluminum-based metal matrix composites (MMCs) are considered in several technological applications owing to their enhanced mechanical properties when compared with monolithic metals. Research on the mechanical properties MMCs was done by many researchers;however in depth study on the oxidation behavior of cenosphere, reinforced MMCs are required, since the application of Aluminum-based MMCs is extensively used in applications like automobile, navigation and aviation, where the demand on light weight corrosion resistance material is very much required. In the present work varied compositions of Al7075 grade Aluminum-cenosphere composites use liquid metallurgy route adopting stir casting approach. The experimental study was aimed at experimental investigations of developed composites under different corrosive environments. The corrosion tests were carried out as per ASTM standards. Salt spray test using NaCl was carried out as per ASTM B117 and immersion tests using NaCl and NaOH as corrodents were carried out by following ASTM G31 standards. The results obtained from the tests revealed that as increase in weight % of reinforcement, corrosion resistance increases up to 7.5% reinforcement, and further the corrosion resistance decreases marginally. Solution heat treated samples exhibited higher resistance to oxidation than cast samples in all corrosive environments. The SEM images show the presence of micro cracks and occurrence of pitting corrosion on the corrosion tested specimens.

Titanium cenosphere syntactic foam with coarser cenosphere fabricated by powder metallurgy at lower compaction load

Titanium cenosphere syntactic foam of varying relative densities with coarse cenospheres was developed through powder metallurgy route at lower compaction loads. The cold compaction load was varied in the range of 60 to 75 MPa to obtain the foams of different relative densities. A function of cold compaction load between crushing tendency of cenosphere and relative density was investigated. The compressive deformation behavior of these foams was studied, and empirical relationships among plateau stress, elastic modulus, densification strains and energy absorption are formulated considering their practical significance. The performance indices of the developed foam in comparison with dense titanium were studied and it was found that the foam is superior alternative to titanium for engineering applications.

Compression behavior and constitutive model establishment of fly ash cenosphere/polyurethane aluminum alloy syntactic foam

The aluminum matrix syntactic foam was fabricated by pressure infiltration technique,and the filling material is syntactic foam material with fly ash cenosphere as the main component and polyurethane foam as the binder.Split Hopkinson pressure bar(SHPB)dynamic compression and quasi-static tests were carried out to examine the compressive response of syntactic foam in this study.Then the dynamic constitutive model was established.Results show that the compressive stress-strain curve of syntactic aluminum foam is similar to that of other metallic foam materials:both kinds of aluminum matrix syntactic foams have strain rate effect,and the syntactic foam has higher compressive strength and energy absorption than the same density aluminum foams.However,due to the different sizes of cenospheres,the dynamic compression results of two kinds of syntactic foams are different,and the energy absorption effect of syntactic foam with small size under dynamic impact is the best.In the range of strain rate and density studied experimentally,the curves of constitutive model fit well with the curves of experimental data.

Effect of Methyl Methacrylate– Acrylonitrile -Butadiene–Styrene (MABS) on the Mechanical and Thermal Properties of Poly (Methyl Methacrylate) (PMMA)-Fly Ash Cenospheres (FAC) Filled Composites

With the advent of plastics and the wide range of fillers that are available have made modifications as precise as the tailored resins themselves. To modify the properties of polymer either by using fillers or by preparation of polymer blends gives rise to new materials with tailored properties. More complex, three-component systems, obtained by the addition of polymeric modifier to polymer filled composites may be of interest. Use of Fly ash cenospheres is very attractive because it is inexpensive and its use can reduce the environmental pollution to a significant extent. In the present study, Poly (Methyl Methacrylate) (PMMA)-Fly ash cenospheres composites were prepared using extrusion followed by Injection molding. The effect of matrix modification with Methyl methacrylate– acrylonitrile -butadiene–styrene (MABS) on the performance of PMMA- Fly ash cenospheres compositions was also, studied. It was found that with the addition of Fly ash cenospheres particulate as filler in PMMA showed marginal reduction in Tensile Strength, % Elongation and Impact strength and improvement in Flexural Strength, Heat Deflection Temperature and Vicat Softening Point. Compared with PMMA-cenospheres composites, the notched Impact Strength of the PMMA/MABS/cenospheres composites showed marginal enhancement in values at higher loading of cenospheres. The optimum performances in mechanical and thermal properties were obtained when the ratio of MABS to cenospheres was 1:2.

Characteristic comparison of metal films coated onto the cenosphere by chemical and magnetron sputtering methods

Metal-coated cenospheres have been widely used in industries. Different coating methods result in different characteristic metal films. The metal film on the cenosphere by chemical coating does not appear to be very smooth, exhibiting metal piled up and pin holes on the surface and leaving some spots uncoated. Meanwhile, the metal film is not tightly absorbed onto cenospheres and is easy to peel off. However, the metal film prepared by magnetron sputtering is compact, smooth and without pin holes. The film has good affinity to the cenosphere surface. Such films do not separate with it even when the cenosphere is crushed. Both the metal t＇rims give the same XRD patterns, indicating that the crystal structure of the metal films by these two methods is the same. Chemical coating is a complex process and harmful to the environment, but it fits ultrafine powder coating （the particle size can be less than 2 μm）. The magnetron sputtering method is environmental friendly and works quickly, but this method requires specially designed equipment and does not work for ultrafine powders. If the particle size is less than 30 μm, the coating process is hard to carry on.

Effect of Micro Size Cenosphere Particles Reinforcement on Tribological Characteristics of Vinylester Composites under Dry Sliding Conditions

In this paper the friction and wear characteristics of vinylester and cenosphere reinforced vinylester composites have been investigated under dry sliding conditions, under different applied normal load and sliding speed. Wear tests were carried using pin on a rotating disc under ambient conditions. Tests were conducted at normal loads 10, 30, 50 and 70 N and under sliding velocity of 1.88, 3.14, 4.39 and 5.65 m/s. The results showed that the coefficient of friction decreases with the increase in applied normal load values under dry conditions. On the other hand for pure vinylester specific wear rate increases with increase in applied normal load. However the specific wear rate for 2%, 6%, 10% and 15% cenosphere reinforced vinylester composite decreases with the increase in applied normal load under dry conditions. The results showed that with increase in the applied normal load and sliding speed the coefficient of friction and spe- cific wear rate decreases under dry sliding conditions. It is also found that a thin film formed on the counterface seems to be effective in improving the tribological characteristics. The specific wear rates for pure vinylester and vinylester composite under dry sliding condition were in the order of 10-6 mm3/Nm. The results showed that the inclusion of cenosphere as filler materials in vinylester composites will increase the wear resistance of the composite significantly. SEM analysis has been carried to identify the wear mechanism.

Effect of Cenosphere Concentration on the Mechanical, Thermal, Rheological and Morphological Properties of Nylon 6

Cenospheres are widely used as filler in thermoset plastics and concrete mainly for density reduction of the material. But there is no work noted of using cenosphere as filler in thermoplastics. In this paper cenosphere concentration was varied from 0 to 10 phr of nylon 6 and the effect of the same on the mechanical, thermal, rheological and morphological properties of the composite were studied. Elongation was found to have increased by 83% and impact strength by 44% at 2.5 phr loading of cenosphere. Flexural strength increased upto 25% at 10 phr content of cenosphere.

Studies in Effect of Low Concentration of Cenosphere on Mechanical, Thermal, Electrical, Crystallinity, Colorimetric and Morphological Properties of Epoxy Cured with Triethylenetetramine

Cenospheres are produced in very large amount in thermal power plants. They are always looked upon as fillers used to reduce the density and cost of the polymer. If cenosphere particles are allowed to remain properly dispersed by taking it in lower concentration, significant improvement in its mechanical, thermal, electrical, crystallinity, colorimetric and morphological properties are expected. To make it happen, epoxy/cenosphere composites were prepared, having lower concentration of cenosphere. Concentration of cenosphere in epoxy, cured with triethylenetetramine, was changed as 0, 3, 5, 7 and 10. Tensile Strength, Tensile Modulus, Percentage Elongation at Break and Crystallinity decreased, whereas, Flexural Strength and Flexural Modulus were found to have increased by 50% and above 100% respectively at 7 phr loading of cenosphere in epoxy. Thermal and electrical stability also increased with increase in concentration of cenosphere in the epoxy, however, the samples became blackish with increased addition of cenosphere. Using SEM analysis it was found that, cenospheres were properly and uniformly dispersed at 7 phr concentration and formed aggregates at 10 phr concentration.

Effect of Heat Treatment on Tensile and Corrosion Properties of LM6 Hybrid Metal Matrix Composite Reinforced with Cenosphere and Red Mud

The increased expectation of automotive, aviation and marine industries pertaining to the enhanced properties and their use in elevated temperature conditions and also corrosive environments leads to the development of the newer material to meet the requirements. The requirements of the automobile and marine applications call for the increased mechanical properties and lower density accompanied with higher resistance to oxidation. Hence the present research work is aimed at the development of Hybrid metal matrix composites (HMMCs) using low-density base material and reinforcements. The aluminum of grade LM6 is preferred material in automobile industries, because it can be cast to any complex geometry and possess good machinability, further upon heat treatment, the properties of LM6 alloy can be enhanced to meet the industry requirements. However, requirements of automobile industries consist of increased mechanical properties, lower density and higher corrosion resistance. Hence, in the present research work, it is aimed to develop newer composite material using LM 6 grade Aluminum alloy as matrix material which is reinforced with varied percent Cenosphere and Red mud.

A Review on Utilization of Light Weight Fly Ash Cenosphere as Filler in both Polymer and Alloy-Based Composites

Fly Ash Cenospheres(FACs)are obtained from the coal power plants in the form of hollow spherical particles by burning the coal.FAC was started to use in early 1980-1985 as lightweight filler material in producing composites of cementitious and at present many researchers are focusing on use of FAC as filler in polymer and metals.In this paper,the systematic review on research activities and application of FAC in manufacturing light weight products are done.The influence of FAC on the physical and mechanical properties of incorporated polymer and alloy-based composites were summarized.Prospects of future for its use were also suggested and summarized in this paper.

莫来石纤维增强氧化物多孔陶瓷及其性能研究

以不同规格的粉煤灰漂珠、长石粉和铝矾土粉为主要原料,引入莫来石纤维为增强相,研究莫来石纤维含量对多孔陶瓷材料性能的影响规律及作用机理。结果表明:高温下长石粉中的低熔相能够降低材料的共晶熔点,将基质间的物理界面结合转变为化学结合。样品经1100℃烧成后,随着莫来石纤维含量的增加,多孔陶瓷的闭口气孔率增加,而常温耐压强度和体积密度呈现先增大后减小的趋势。当莫来石纤维含量为10 wt.%时,材料具有最佳综合性能,其体积密度为(0.74±0.01)g·cm^(−3)、真气孔率为(72.70±0.58)%,常温下耐压强度为(7.30±0.64)MPa。此外,试样在300℃、600℃及900℃下的平均热导率分别为0.202 W·m^(−1)·K^(−1)、0.214 W·m^(−1)·K^(−1)及0.244 W·m^(−1)·K^(−1)。

轻质漂珠对HPMC/水泥基复合多孔保温材料性能的影响

为获得性能良好的羟丙基甲基纤维素(HPMC)/水泥基复合多孔保温材料,研究了不同掺量漂珠(FACs)对HPMC/水泥基复合多孔保温材料力学性能、导热系数、干密度、吸水性的影响,同时运用SEM、XRD等方法以及图像分析软件对复合材料气孔孔结构特征进行表征。研究表明,随着FACs掺量增加,导热系数呈先降低后增加的趋势,抗压强度先增大后降低。当FACs掺量为9.0%(质量分数)时,复合材料的导热系数最小,为0.094 W/(m·K),28 d抗压强度为1.58 MPa,干密度为418.9 kg/m^(3);当FACs掺量为18.0%时,复合材料的抗压强度最优,28 d抗压强度为2.15 MPa,导热系数为0.101 W/(m·K),干密度为431.0 kg/m^(3);随着FACs掺量增大,复合材料小于300μm的气孔比例逐渐增大,平均孔径呈降低趋势。

PEG/漂珠复合相变材料的表征及性能研究

为了研发适用于高温环境下沥青路面的复合相变材料,本研究以PEG2000作为相变材料,漂珠作为载体,利用PEG2000优良的相变特性及漂珠的高强度特性,制备出一种高强度且耐高温的复合相变材料(composite phase change materials,CPCMs)。制备的CPCMs在相变储热性能上表现较好,同时具有优良的化学稳定性、兼容性及热稳定性。当CPCMs的掺量达到60%时,测温试件之间的最高温差仅为2.8℃,峰值温度出现的时间延迟了2.1 min,对路用性能也产生了不利影响。因此,适量CPCMs能够有效调控沥青混合料温度。该研究结果为沥青路面的降温调控提供了参考。