Influence of iron–aluminum alloy on the tribological performance of non-asbestos brake friction materials – a solution for copper replacement

Abstract

Purpose The purpose of this study is to investigate the influence of commercially available iron–aluminum alloy compared to copper, iron and aluminum powders on the tribological performances of friction composites. The main objective is to replace copper from the friction composite formulations. Design/methodology/approach In this study, friction composites were fabricated as of standard brake pads using commercially available iron–aluminum alloy and compared to copper powder, iron powder and aluminum powder-based without varying the other ingredients. The brake pads were developed as per the industrial procedure. The physical, mechanical and thermal properties of the developed brake pads were analyzed as per industrial standards. Tribological properties were analyzed using the chase test. Initial speed and deceleration tests in a real-time braking scenario were performed using a full-scale inertia brake dynamometer. Worn surface analysis was done using a scanning electron microscope. Findings The results indicate that iron–aluminum alloy (mechanomade)-based friction composites possess good physical, chemical, thermal and mechanical properties with stable fade and recovery characteristics due to its composition and flake morphology. During initial speed and deceleration braking conditions, iron–aluminum alloy also showed good tribological behavior. Originality/value This paper explains the influence of commercially available iron–aluminum alloy in friction composites in enhancing tribological performance by its composition and flake morphology, which could potentially replace copper in friction composites by solving subsequent problems.