Role of metal composite alloys in non-asbestos brake friction materials-A solution for copper replacement

Abstract Copper plays a vital role in the performance of brake friction materials due to its better thermal conductivity and fade resistance. But owing to the negative impact towards to the aquatic life, the usage of copper in brake material formulations is reduced considerably in developed nations. Research is being carried out globally to reduce the copper with single ingredient or combination in brake materials. Thus the present study dealt with the development of brake pads using a commercially available alloy of aluminum and iron (Mechanomade) in the formulation with other ingredients. To compare the performance, three other brake pads were also developed by replacing mechanomade with copper, aluminum, and iron in the formulation. The developed brake pads were analysed for the physical, chemical, mechanical and thermal properties as per standard industrial practice. The tribological characteristics were analysed using Chase test following SAE J661. It was evident from the test results that Iron aluminum alloy based brake pads showed good fade and recovery characteristics. To study in detail regarding the worn surface characteristics, Scanning Electron Microscope with Elemental mapping was used.