Non-linear mechanical behavior of a sintered material for braking application using digital image correlation

Friction materials for braking applications are complex composites made of many components to ensure the various performances required (friction coefficient level, low wear, mechanical strength, thermal resistance, etc.). The material is developed empirically by a trial and error approach. With the solicitation, the material evolves and probably also its properties. In the literature, the mechanical behavior of such materials is generally considered as linear elastic and independent of the loading history. This paper describes a methodology to characterize the mechanical behavior of such a heterogeneous material in order to investigate its non-linear mechanical behavior. Results from mechanical tests are implemented into material laws for numerical simulations. Thanks to the instrumentation, some links with the microstructure can also be proposed. The material is made of a metallic matrix embedding graphite and ceramic particles and is manufactured by sintering. It is used for dry friction applications such as high-energy brake for trains, cars and motorcycles. Compression tests are done with digital image correlation to measure full-filled displacement. It allows to calculate strain fields with enough resolution to identify the material heterogeneity and the role of some of the components of the formulation. A behavior model of the material with plasticity and damage is proposed to simulate the non-linear mechanical behavior and is implemented in an FEM code. Results of mechanical test simulations are compared with two types of experiments showing good agreement. This method thus makes it possible to determine mechanical properties at a virgin state but is extensible for characterizing a material having been submitted to braking solicitations.