Optimization of eggshell particles to produce eco-friendly green fillers with bamboo reinforcement in organic friction materials

Abstract

Abstract The environment is a very important topic today as well as in the future. One source of air pollution that has the potential to harm health is the wear particles released by vehicle braking systems. If these wear particles come from hazardous materials, they could destroy human health and the environment. Based on these conditions, exploring more environmentally friendly materials to substitute hazardous materials as friction materials is necessary. In this study, brake linings were prepared from bamboo fiber and eggshell (ES) particles with various pre-treatment conditions. The composition of the material frictions consisted of phenolic resin, bamboo fiber, bamboo particles, ES particles, zinc, alumina, and graphite in the following: 35% phenolic resin, 10% graphite, 10% bamboo fiber, 10% alumina powder, 5% zinc powder, and 30% bamboo particles and ESs. This study focused on observing the mechanical and tribological behavior of friction materials when using ES particles as fillers. There are three stages to manufacturing friction material: a cold press, a hot press, and heat treatment. The optimization of the characteristics of ESs as organic brake linings was carried out using the Taguchi method and analyzed using data envelopment analysis-based ranking (DEAR). An interesting finding from this study was that when ES particles were calcined at 900°C for 120 min, the ES particle size was 200 mesh, and the ES volume fraction at 25% resulted in the most optimal brake lining performance. Calcination at 900°C for 120 min completely changed the CaCO3 phase to CaO. This study also shows that calcined ES particles have the potential to be developed as friction materials for environmentally friendly two-wheeled vehicles in the future. The produced brake linings exhibited hardness, a coefficient of friction, and specific wear rates of 92.82 HR, 0.32, and 4.43 × 10−6 mm3·N−1·m−1, respectively.