Wear Behavior of Commercial Copper-Based Aircraft Brake Pads Fabricated under Different SPS Conditions

Understanding the wear behavior of Cu-based brake pads, which are used in high-speed railway trains and aircraft, is essential for improving their design and safety. Therefore, the wear mechanism of these pads has been studied extensively. However, most studies have focused on the changes in their composition and not the effects of their manufacturing conditions. In this study, we fabricated commercial Cu-based brake pads containing Fe, graphite, Al2O3, and SiO2 using spark plasma sintering under different conditions. The microstructures and mechanical properties of the pads were investigated. The pads were tribo-evaluated using the ball-on-disc test under various load conditions. Their worn surfaces were analyzed using X-ray diffraction analysis, scanning electron microscopy, energy-dispersive X-ray spectroscopy, and confocal microscopy in order to elucidate their wear mechanism. In addition, the dynamometer test was performed to confirm whether their wear behavior would be similar under actual conditions. Finally, a comparative analysis was performed using the ball-on-disc test. The results indicated that the brake pads with the same composition but fabricated under different sintering conditions exhibited different wear characteristics. We believe that this research is of great significance for understanding the wear mechanism of Cu-based brake pads and improving their design and hence their performance.