Review of Brake Friction Materials for Future Development

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Review of brake friction materials for future development

K. Naresh Kumar a *, Dr. K. N. S. Suman b

a * Assistant Professor, Mechanical dept, Anits Engineering college, Visakhapatnam b Assistant professor, Mechanical dept, Andhra University, Visakhapatnam

Abstract Braking system in an automobile is always considered to be important for the designers. The main function of a braking system is to overcome vehicle’s momentum and stop the vehicle by means of friction. Now days, with the increase of innovative technology and by varying design procedures, newly designed automobiles with high speed sprung on to the market, which are throwing prime challenges for the braking system designers to control the speed of the vehicle. After the gradual phasing out of asbestos as a braking material in many parts of the world, due to its widespread complaints as a carcinogenic material, automobile brake friction industry and people are looking for suitable alternatives to replace asbestos material. There is need to develop new friction materials to meet the stringent requirements of customers, such as effective braking performance and less squealing action .Therefore, the main challenge for the designer is to develop a brake friction material which intended to serve its effective braking performance and being eco friendly in nature. Therefore, with in this paper, an overall review of the research carried out in the area of friction materials is presented and the affect of fiber, filler and other ingredients on the braking performance is studied. Various experimental techniques used to study the behavior of squealing action in automobile braking is presented.

Key words: Brake friction materials, friction and wear, squealing, fade, recovery

a* Author correspondence Email: [email protected] , Tel: 91-9949717058

1. INTRODUCTION material temperature, friction material Brake pads convert the kinetic energy of contact area, friction material finish, heat the vehicle to thermal energy by means of removal rate, ability to operate over friction. Two brake pads are contained in various atmospheric conditions and fade the brake caliper with their friction resistance. In addition to all these factors, surfaces facing the rotor. When, the brakes the other factors that affect the friction are hydraulically applied, the caliper development are weight transfer, tire and clamps or squeezes the two pads together road conditions, dimensions of brake in to the spinning rotor to slow/stop the drum, engine size and drive train gearing, vehicle. During this process, the pads are and water on brake linings etc. subjected to wear. The wear rate mainly Fig 1 & 2 shows a typical disk brake and depends up on the type of friction material assembly found in passenger vehicles. used, pressure applied on the pads, friction

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Fig1. Automobile disc brake with friction material

Fig 2. Assembly of automobile disc with friction material

The main characteristics of friction 1.1 Classification of friction materials materials should possess are [1] In the past, asbestos reinforced fiber (a) Maintain a sufficiently high coefficient friction material is widely used because of of friction with the brake disc. its excellent comprehensive performance (b) Not to decompose or break down in such as low density, high mechanical such a way that the friction coefficient properties, high melting point, high with the brake disc is compromised, at friction coefficient, and less wear rate on high temperatures. disc. It has been proved recently, that (c) Exhibit stable and consistent asbestos is carcinogenic to human coefficient of friction with the brake respiratory organs and cannot be used as a disc. friction material [2, 3]. Based on the type (d) Wear resistant. of matrix material, brake friction materials (e) Able to dissipate heat to the can be divided in to metallic, Semi surroundings. metallic, and non metallic. (f) Having sufficient fade resistance. 1.1.1 Metallic matrix friction material (g) Induce less squealing action and Depending up on the type of production should be operated over different technique, the metallic matrix friction atmospheric conditions. materials can be divided in to two types i.e. metal casted and powder metallurgical. Steel, cast iron, bronze etc. can be

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categorized as main constituents for metal exhibits high strength and toughness and casted friction materials. Powder superior thermal stability. At present, C-C metallurgy friction materials mainly Composite friction material was mainly include iron based, copper based and used in aero planes and race cars. combination of iron and copper based. Among the above mentioned classified Among them, iron based friction materials friction materials, Powder metallurgy and has high temperature strength, hardness, organic friction materials are widely been and thermal stability. While, the copper used in various applications. Organic based friction materials has more stable friction material was most widely used due friction coefficient, greater thermal to its simple preparation method, excellent conductivity and wear resistance. Iron and tribological properties and eco copper combination made friction friendliness. Organic friction material materials having same content of copper consists of following components [1] and iron possess excellent mechanical (a) Binder: The binder sticks all properties and good wear resistance. components together. The binder Powder metallurgy friction materials are selected, should possess excellent heat widely used in trucks and trains having a resistance. heavy braking load and extremely high (b) Reinforcing fibers: The Reinforced speed. fibers are used to improve friction performance and strength. 1.1.2 Semi metallic matrix friction (c) Frictional additives: Frictional material additives are responsible to improve Semi metallic friction material consists of friction properties of the brake pads combination of fibers and metallic and they are comprised of a mixture of powders. Prominent fibers predominantly abrasives and lubricants. The lubricant in use are ceramic, metallic, carbon and is generally used to reduce the wear of aramid. Whereas metallic powders are friction material and coefficient of mainly of copper and iron. These friction and abrasive is used to materials possess excellent tribological improve the coefficient of friction. properties and high heat resistance. The (d) Fillers: Fillers are used to improve the main disadvantages of semi metallic manufacturability of brake pad and matrix friction material are low frequency reduce the cost. noise, easy rusting, and serious damage to 2. Friction and wear behaviors of brake disc. Presently, semi metallic matrix various materials friction material is widely used in Friction and wear behaviors of friction automobiles, motor cycles and other light material depend mainly on the following weight vehicles. important factors [4] a) Selection of friction material for 1.1.3 Nonmetallic matrix friction material fabrication. Non metallic matrix friction material b) Manufacturing method involved for consists of organic fibers such as Kevlar, fabrication. Carbon etc. as reinforced fibers in c) Material characteristics such as combination with other ingredients such as Physical, chemical and mechanical modified resin by rubber powder, properties of friction materials. frictional additives, and filler materials. d) Braking influential parameters such as These materials are solidified by pressing braking pressure, initial braking against hot press. There are a number of speed, braking time, temperature rise nonmetallic matrix friction materials, out in braking etc. of which carbon –carbon friction material

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e) Other Conditions such as Surrounding natural fiber composites and their temperature, humidity, air flow etc. mechanical Performance. It was observed f) Structural parameters such as Shape, that the mechanical properties of the fiber size, contact of brake pair etc. are improved due to inclusion of various Friction material characteristics play a filler materials. There is need to improve vital role to improve the performance of moisture resistance of the fiber in future. materials. Among, the different types of Emad omrani, Pradeep L Menezes [6] materials available for manufacturing, investigated about tribological behavior of organic type of composite materials are polymer matrix composites reinforced widely used in the industry. Now a days, with natural fibers and observed that composite materials plays a promising chemically treated natural fiber gives good role in several fields of applications like tribological behavior and better friction aerospace, automobiles, sports items, compared to untreated conventional fibers. bridge construction and pressure vessels The type of chemical treatment and fiber etc.. The advantages of composite orientation are two important parameters materials are ease of process ability, less to concentrate in order to achieve good weight, corrosion resistance, low cost and strength. Umar Nirmal , Jamil Hasim [7] high specific strength to weight ratio. Reviewed on tribological Performance of Among the different types of composite natural fiber polymeric composites and materials available, fiber reinforced identified the key parameters such as composite materials plays a prominent role adhesive wear mechanism, operating and in several applications because of their test parameters plays an important role in excellent mechanical properties, corrosion tribological properties. M.A.Maleque, resistance and good strength to weight A.Atiqah [8] Fabricated natural fiber ratio. The selection fiber, filler, braking reinforced aluminum composite for conditions plays a key role in the design automotive brake pad. In this work brake and manufacturing of friction materials. pads are formulated by the following Therefore, the influence of these ingredients namely, Aluminum (45wt %), parameters on friction and wear behavior Silicon Carbide (20 wt %), Coconut fiber is studied in detail to select the appropriate content is varied from four different friction materials for effective braking formulations(0,5,10,15wt%), performance. graphite(10wt%),Alumina oxide(13wt%), Zirconium oxide(2wt%), Phenolic 2.1 Influence of reinforced fiber on Resin(10wt%). It was observed that, friction and wear coconut fiber containing (5, 10 wt %) Selection of fiber reinforcement material showed better physical and mechanical plays an important role for the designer to properties compared to other formulations. improve friction and wear characteristics Xingming xiao, Yan Yin [4] Reviewed on of friction material. Fiber is responsible for the friction and wear behavior of brake transmitting the given load and materials. In this work friction material withstanding the given pressure. It gives classification, friction interface and mechanical strength to the entire formation of various friction films has composite. Selection of optimum wt% of been studied. It was observed that the the fiber is essential for the designer to temperature, Velocity, and pressure plays achieve better wear and frictional an important role in the friction and wear properties. behavior of friction materials and the wear rate induced in friction material is directly K.L.Pickering, M.G.Aruan Efendy [5] proportional to the operating parameters. Reviewed on recent developments in

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N.Aranganathan, Vishal Mahale. [9] properties increase with increase in aramid Formulated an aramid fiber non asbestos fiber content. The composite having organic friction composite. In this work, lapinus to aramid ≥ 25% to ≤ 5% and the friction composite is formulated by Phenolic Resin 15%, BaSO4 50%, following ingredients, phenolic Resin (10 Graphite 5% showed better braking and wt %), Fillers (Brass metal powder 10 fade performance. Whereas, composite wt%, cashew dust 10 wt%, vermiculite 10 with lapinus content ≤ 22.5 % and aramid wt %), Friction modified fibers (Grapite10 content ≥7.5 % proved best from recovery wt%, Alumina 2 wt%, Rock fibers 10 and wear performance. wt%, Glass fibers 5 wt%, PAN fibers 3 Vivek Dhand, Garima Mittal [12] wt%), BaSO4(30,28,26,24,22,20wt%), Reviewed on basalt fiber reinforced Aramid fiber ( 0,2,4,6,8 wt%) . The aramid polymer composites and observed that the fiber content is varied in proportions and mechanical properties of basalt fiber were physical, mechanical, chemical and improved by hybridizing basalt fiber with tribological performance is evaluated. It silanes. Hence, basalt fiber can be was observed that 10 wt % Aramid pulp successfully used in industries like showed best performance in coefficient of transport, mining engineering, civil friction (µ), µ fade, and µ recovery. Peng infrastructure and environmental Cai, Zhenlian Li. [10] investigated about applications. V.Fiore, T.Scalici [13] the effect of aspect ratios of aramid fiber reviewed on basalt fiber and its composites on mechanical and tribological behaviors .In this work basalt fiber is used as of friction materials. The friction material reinforcement in composites because of its is fabricated with the composition of good thermal, chemical and mechanical K2Ti6O13 29.2%, aramid fiber 18%, NBR properties. Ashok Kumar Ilanko, 1.7%, Vermiculite 18%,Potash feldspar Srinivasan Vijayraghavan [14] studied 2.6 %, flake Graphite 4.3 % , BaSO4 2.6% about, wear behavior of asbestos free eco , Boron Phenolic resin 23.6%. It was friendly composites for automobile brake observed that, by increasing the aspect materials. In this work three different ratio of fiber, flexural strength of the brake pad materials flax fiber reinforced composite increased and compressive phenolic composites (FFRC), Basalt fiber strength decreased while the coefficient of reinforced phenolic composites (BFRC) friction (μ) and wear rate of composite and flax/Basalt reinforced hybrid phenolic first increased and then decreased at composites (HFRC) has been studied for selected load and speed. And With the various thermal, mechanical and physical addition of fibers, the coefficient of properties. Brake pad is formulated with friction (μ) and wear of the composite is the following ingredients namely, Phenolic increased. It was observed that, Aramid resin 25 wt%, fillers (barites 15 wt%, pulp of 10 vol% is proved to be the best vermiculite 5 wt %), friction modifiers optimal volume fraction for improved (Graphite 12 wt%, coke 18 wt %, MoS2 friction and wear behavior of the 1 wt %, MgO 5 wt %, potassium titanate 6 composite. T.Singh, A.Patnaik[11] wt% , Al2O3 5 wt%, ZrSiO4 2 wt %), Developed hybrid phenolic composites reinforcement (flax, basalt, flax/basalt 6 wt based on lapinus and aramid fiber. The %).It was observed that, BFRC for pad contents of aramid fiber and lapinus fiber exhibit good thermal and wear are varied in proportions by keeping characteristics because of its good bonding remaining compositions as constant. It is strength with resin. B.K.Satapathy, J.Bijwe observed that physical properties increase [15] studied the performance of friction with increase in lapinus fiber content and materials based on variation in nature of mechanical and thermo mechanical organic fibers. In this work, the influence

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of organic fibers such as Aramid, PAN, hardness of the samples increases. The Carbon fibers and cellulose fiber on the samples containing 25 wt% resins in coefficient of friction (μ), fade and μ uncarbonized banana peels and 30wt % recovery characteristics of the composite is carbonized banana peels have the best determined. It was observed that carbon properties. K.K.Ikapambse, D.T.Gundu fiber reinforced composite showed high [19] Used palm kernel fibers for the resistance to coefficient of friction (μ) fade production of asbestos free brake pad with where as cellulose fiber composite showed epoxy resin as the binder .Resin is varied least resistance to μ fade. The composite in proportions by keeping the remaining containing Aramid fiber and cellulose fiber compositions as constant. It was observed exhibits highest and lowest wear resistance that sample s6 with composition of 40% where as highest and lowest coefficient of epoxy Resin, 10% palm wastes, 6%Al2O3, friction is observed for cellulose and 29% Graphite and 15% CaCO3 gave better carbon fiber based composites. Bhabani properties than the other samples. K.Satapathy, Jayashree Bijwe [16] studied Therefore, Palm kernel fibers can be used about influence of operating variable on as a replacement for asbestos in brake pad friction composite. Organic fibers such as applications. aramid, PAN, Carbon and Cellulose is studied with respect to the braking Nagesh S.N, Siddaraju C[20] characterized pressure and speed. It was observed that, brake pads by variation in composition of carbon and PAN made the friction friction materials. Three brake pad S 2, S3, composite least sensitive to dynamic & S 4 are manufactured and compared variations. The inclusion of cellulose fiber with the existing brake pad sample S1. tends to increase the friction coefficient Brake pad sample S2 exhibits good while aramid fiber improved wear properties and the constituents are, Steel resistance. A.P. Garshin, V.I.Kulik. [17] wool (26.2wt%), Vermiculite( 20 wt %), Reviewed on new generation of braking Natural Graphite( 10 wt%) ,Carbon black ( friction materials such as carbon and 3. wt%), Ceramic fiber (17.7wt %), ceramic matrices. An attempt is made in Phenolic Resin (21.5wt %) . Brake pad this paper to formulate a carbon Ceramic sample S3 is manufactured with Steel matrices fiber reinforced composite wool ( 29.2 wt %), Vermiculite ( 20 .8 wt friction material to reduce the mass of the %) , Natural Graphite( 4.6 wt%) , Carbon braking system by 40-60%. It will have black ( 2.3 wt%) , Ceramic fiber ( 20wt high wear resistance and ability to resist %), Phenolic Resin (22.3 wt %) .Brake pad temperatures over 1273 K, and can be sample S4 is manufactured with Iron oxide successfully used as friction materials in (27.7 wt %) , Barytes(18.5 wt%), Natural aerospace vehicles. Graphite( 8.5 wt%), Carbon black ( 3.8 wt%), Mineral fiber(18.5 wt%), Phenolic U.D.Idris, V.S.Aigbodion [18] developed Resin (23.1 wt %). It was observed from eco friendly asbestos free brake pad using the pin on disc apparatus, the brake pad banana peels. In this work asbestos free sample S2, wear slightly high and the brake pad using banana peels as coefficient of friction was almost stable reinforcement phenolic resin as the binder and slightly less compared to the existing is formulated and tested for different specimen S1. The coefficient of friction morphology, physical, mechanical and for the sample S4 was slightly high around wear properties. The resin content is varied 0.45, due to the presence of higher from 5 to 30 wt%. It was observed that percentage of abrasive which increases the with the increase in wt% of resin friction coefficient and wear rate. The compressive strength, specific gravity, shear strength of the new prepared

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specimen showed better values compared friction materials (GFRFM, AFRFM and with existing brake pads. Hence brake pad CFRFM) was studied in the temperature sample S2 and S4 can be used in place of range of 1000 C-3000C.It is observed that existing brake pad and the cost of CFRFM shows less wear rate compared to producing these brake pads are quiet low. GFRFM &AFRFM. Zhishuang Dai, R.Vijay, M.Jeesh Janesh [21] optimized Baoyan Zhang [24] evaluated the effect of the tribological properties of non asbestos heat treatment on Carbon fiber surface brake pad materials using steel wool. properties and fiber/ Epoxy interfacial Friction material is formulated with the adhesion. In this work T 300 B fiber was following ingredients , steel wool(0wt%, 4 heat treated and the effect of heat wt%,8wt%,12wt%),copper fiber (5wt%), treatment was studied by means of x-Ray Antimony trioxide(1.5 wt%) ,Alkyl photo electron spectroscopy (XPS) and Benzene Phenolic Resin(11wt%),NBR inverse gas chromatography (IGC) Rubber(3wt%),Syntheticgraphite(10wt%), analysis. It was observed that the Molybdenum disulphide(2wt%),Zirconium dispersive surface energy of T 300 B silicate(2wt%),Frictiondust(12wt%),Synth carbon fiber and contact angle between eticbarites(32wt%),Vermiculite(7wt%),Cal carbon fiber and epoxy E51 increases, cium carbonate(14.5 wt%). The steel wool while the interfacial shear strength of T content is varied in proportions by keeping 300 B / epoxy reduces with the heat the remaining ingredients as constant. It treatment process. Kannan was observed that the non asbestos Balasubramanian and Marko Burghard organic (NAO5) with high steel wool [25] Reviewed on Chemically content showed better properties and Functionalized Carbon nano tubes. Carbon exhibits good coefficient of friction and nano tubes possess good structural, less wear rate than other compositions. mechanical, and electronic properties. Sedigheh Bagheri Kazem Abadi, Alireza Chemically functionalized CNT can be Khavandi [22] fabricated a brake friction used in several applications for improving material with phenolic resin, short carbon all the mechanical properties of the fiber, graphite, quartz, barite and steel composite. R.Andrews, M.C.Weisenberger fiber .The effect of mixing steel and [26] Reviewed Carbon nano tube polymer carbon fibers on the friction and wear composites. In this review CNT/polymer properties of a polymer matrix composite matrix composite is studied in detail with friction material is studied in detail. The main emphasis on toughness and bonding ingredients of steel fiber (17.5 wt%,15 strength. Jia xian and Ling xiaomei [27] wt%,12.5 wt% ,10wt% ) and carbon fiber studied the friction and wear (2 wt%,3 wt%,4 wt%,5 wt%) are varied in characteristics of polymer matrix friction the given proportions, and it was observed materials reinforced by brass fibers. In this that sample containing 4 wt% Carbon fiber work, the influence of organic adhesion exhibits better wear and friction properties. agent, cast iron debris, brass fiber, and Du-Qing CHENG, xue-tao WANG [23] graphite powder on the friction wear studied the effect of friction and wear characteristics is studied in detail. The behavior of carbon fiber reinforced brake experimental results showed that the materials. A new composite brake material friction coefficient and wear loss of the was fabricated with metallic powders (40 friction material increased with the Wt %), barium sulphate ((17-23Wt %) and increase of cast-iron debris, but decreased modified phenolic resin (25 Wt %) and with the increase of graphite powder carbon fiber (12-18 wt %).The friction, content. When the content of organic wear and fade characteristics of the glass, adhesion agent is about 10-11%, the asbestos and carbon fiber reinforced friction material has a higher friction

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coefficient and lower wear rate. D Chan select the of type of fiber for the required and G W Stachowiak [1] reviewed on application to achieve good wear rate and automotive brake friction materials stability of coefficient of friction, But, .Various types of brake friction materials other parameters like filler ingredients , after the phasing out of asbestos is method of fabrication ,temperatures presented. The advantages and generated at the contact region, speed will disadvantages of various brake pads are affect the strength of the composite. Below studied. It was observed from the review tables 1&2 and figures 2.1 (a) &2.1 (b) that there is need to develop automobiles will give an overall idea to select with high efficiency and lower emissions appropriate fiber volume % with respect to considering all the environmental wear rate and coefficient of friction. The regulations. following notations are used for plotting graphs for different fibers with respect to Based on the work carried out by many volume%, wear rate and coefficient of researchers, it was observed that, fiber friction. [NF-Natural fiber, AF-Aramid selection and the chemical treatments fiber, GF-Glass fiber, RF-Rock fiber, LF- affect the strength of the composite. Lapinus fiber, BF-Basalt fiber, CF-Carbon Further, it improves interfacial adhesion fiber, SF-Steel fiber, PKF-Palm Kernel between fiber and matrix and improves the fiber, Cellulose fiber, Copper fiber, shear strength of the composite. Although Ceramicfiber]. the data presented here may be helps to

Table1.Selection of fiber based on volume% and wear rate

Wear rate Type of fiber Volume% /10-6mm3/Nm NF 8 8 NF+Treat ment 12 15 NF coconut+Al+SIC 10 28 AF+GF+RF+PAN 10 34 AF+K2Ti6013 10 30 AF+LF 30 38 BF 7 30 BF+FF 12 32 CF+AF+CelluloseF 14 44 BF carbunized 30 19 PKF 10 32 SF+Ceramic F 49 42 SF+Copper F 18 48 SF+CF 17 52 C,GF,SF 16 39

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Fig 2.1(a) Effect of wear rate on fiber volume %

Table 2. Selection of fiber based on volume % and coefficient of friction

Type of fiber Volume% Coefficient of friction NF 8 0.28 NF+Treat ment 12 0.3 NF coconut+Al+SIC 10 0.35 AF+GF+RF+PAN 10 0.4 AF+K2Ti6013 10 0.5 AF+LF 30 0.4 BF 7 0.38 BF+FF 12 0.4 CF+AF+CelluloseF 14 0.42 BF carbunized 30 0.3 PKF 10 0.35 SF+Ceramic F 49 0.45 SF+Copper F 18 0.52 SF+CF 17 0.54 C,GF,SF 16 0.4

Fig 2.1(b) Effect of coefficient of friction on fiber volume %

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It was observed from the above graphs, with necessary ingredients for the design , that the wear rate of friction material which suits to given operating and human mainly depends up on the temperatures comfort conditions. generated at the contact region between friction material and disc. Fiber material N.Aranganathan, Jayashree Bijwe [28] and other ingredients selected for the developed copper free eco friendly brake design should be able to with stand the friction materials by using novel temperatures generated at the contact ingredients. In this work an alternative two plateaus to have sufficient fade resistance. new filler materials rock fiber and thermo Therefore optimum selection of fiber graphite fiber is selected for manufacturing compromising with the given temperatures a brake pad. Five brake pad materials of and pressure has to be selected to have Cu free rock fiber increasing Wt %( 10, stable coefficient of friction over wide 15, and20 %) is fabricated along with 10% range of temperatures. thermo Graphite. Physical and mechanical properties of the Cu based and Cu free 2.2 Influence of metallic / organic fillers based brake pad composite is evaluated. on the wear and coefficient of friction It was observed that Cu- based friction Selection of metallic / organic fillers and materials perform better than Cu –free other ingredients are selected based on the friction materials in some properties but friction material usage for any application. not significantly in main important Operating parameters such as speed, properties. Glenn Kwabena Gyimah, Ping braking conditions will affect the selection Huang [29] developed a novel type friction of filler material. Because, the filler material with Cu and Several elements material has to with stand the given load at such as Al, SiO2, Fe, Graphite, Sn, Mn, various speeds of the automobile. Various and MOS2 by powder metallurgy other parameters such as, manufacturing technique. The effect of sintering conditions, bonding strength between all temperature was studied on the mechanical ingredients, operating conditions, design and tribological characteristics of train conditions, atmospheric conditions affect brake pads. The materials prepared are the selection of filler materials. The ease sintered at three different temperatures of manufacturing of friction material also (8500C, 9000C & 950 0 C). It is observed depends on the selection of filler material. that severe wear occurs at lower temperatures (8500C, 9000C) but wear Generally metallic filler material is reduced at the elevated sintering included in the friction material to with temperature of 950 0 C. It is also observed stand high temperatures. It is generally that the porosity reduced at higher used for high speed vehicles like trains and sintering temperature. The densification of sports cars. Now a day’s metallic filler the material was also improved. The materials are replaced with organic filler volumetric and wear coefficients improve materials to reduce vibrations generated remarkably with increase in sintering during braking. Organic filler materials are temperature. Further increase of sintering used for low and medium speed vehicles. temperature above 950 0 C is expected to Few, researchers are also studied about affect the microstructure and tribological semi metallic friction material, to characteristics of Cu based friction compromise for both strength and material. Ane Maite Martinez, Jon vibration. The appropriate selection of Echeberria [30] investigated about the filler material is given as a choice for the reaction between metal powders and the designer to consider better filler material solid lubricant Sb2S3 in a low metallic

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brake pad at high temperature. Metal of the composite increases. The coefficient sulphides such as Cu, Fe, Sn, and Zn play of friction obtained is within the an important role during braking. The recommended standard for automobiles. effect of metal sulphides on solid lubricant A.Almaslow, M.J.Ghazali [34] made an Sb2S3 plays an important role. It was attempt to include natural rubber alumina observed that, the reaction features and nano particles in friction composite. In this products depend on the temperature paper, friction composites consisting of generated during braking, the specific epoxidized natural rubber alumina nano combination of metal lubricant and the particle (ENRAN), steel wool, graphite, atmospheric conditions. and benzoxazine were prepared using a Guangyu bian, Houzheng wu [31] studied melt mixing method. The mixing work about friction surface structure of a carbon was carried out at 90 0 C. It was observed SiC Cf / C- SiC composite using a that Samples with 29% of ENRAN dynamometer. A thin friction layer was exhibited the best friction coefficient of developed on the top of transferred 0.437 with low specific wear rate of 0.27 x materials and SiC regions with nano sized 10-7 cm3 / Nm. Raffaele Gilardi, Luigi copper/iron oxide crystallites as the Alzati [35] Studied about Copper primary constituent. The main chemical substitution and noise reduction in brake elements in the friction layer on the brake pads by graphite type selection. Graphite disc surface are Fe,Cu,O,Si and FeO powder is mainly used in brake pads. The crystallites in a size around ten nanometers role of graphite is acting like a solid . It was observed that the bonding strength lubricant and coefficient of friction between carbon and SiC proved to be stabilization. In this work, brake pad weak, and stable coefficient of friction consisting of phenolic resin (18 wt %), cannot be achieved due to poor bonding mineral fibers& Aramid pulp (5wt %), strength between fiber and matrix. cashew dust (10wt %), BaSO4 (49wt %), Guangyu Bian, Houzheng wu [32] Studied graphite powder (8wt %) is mixed and hot about Friction performance of carbon pressed following curing operation. Noise, /Silicon Carbide Ceramic composite vibration and harness tests are conducted brakes in ambient air and water spray on the samples. It was observed that environment. In this work, carbon / Silicon graphite increases the thermal conductivity carbide brake disc having composition of brake pads. Synthetic graphite T150- 53.1% and, 17.7 % Sic composite is tested 600 (Particle size less than 75micro against an organic brake pad in air and meters) gives higher in plane thermal water spray environment. It was observed conductivity compared to KS150-600.It that an average coefficient of friction of was also observed that, copper free resin 0.52 and 0.4 was observed for a braking bonded brake pads combining with stop in air and coefficient of friction of 0.1 synthetic graphite C-THERM011 gives the was observed for water spray environment. best results in terms of Noise vibration Repeated braking reduces the coefficient harness (NVH) performance and heat of friction and reduction of Sic content in dissipation. the brake disc. S.G.Amaren, D.S.Yawas [33] made an attempt to include Mukesh Kumar, Jayashree Bijwe [36] periwinkles shell particle size on asbestos studied about non asbestos organic (NAO) free friction composite. In this work the friction composites, role of copper, its periwinkle shell particle size of +125 μ m shape and amount. In this work, two types to + 170 μ m is varied in proportions. It of friction composites by varying the was observed that, with increasing amount of copper powder and fibers (0, operating parameters, the wear resistance 10, 20 wt %) were developed and tested. It

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was observed that, inclusion of copper used as a binder. The results show that two improves major performance properties. It of the nano porous materials generated 3-7 is also observed that 10 wt % of filler size times less airborne wear particles than the considered to be the best filler size in conventional brake materials. terms of wear and coefficient of friction. N Aranganathan, Jayashree Bijwe [37] Tej Singh, Amar patnaik, Bhabani K. carried out a comparative performance on Satapathy [39] studied the effect of nano NAO friction materials containing natural clay reinforcement on the friction braking graphite(NGC) and thermo graphite(TGC). performance of hybrid phenolic friction In this method two friction materials composites. In this work, nano having natural graphite and thermo clay/lapinus fibers content (2.75wt%- graphite is prepared with the following 2wt%)/(27.5wt%-20wt%) is decreased and ingredients , phenolic Resin 8 wt%, graphite/aramid fibers content(2.25wt%- Fillers( Vermiculite 10 wt%, Potassium 3wt%)/(2.5wt%-10wt%) is increased and titanate 10 wt% , Cashew dust 10 wt% , master batch of phenolic/barite copper 15 wt%,) Barytes 14 wt% , Fibers composition (15wt%)/(50wt%) is designed (Glass fibers 5 wt%, PAN fibers 3 wt%, ,fabricated and characterized for their Rock wool 1 10 wt%) , Friction modifier mechanical, thermo-mechanical and abrasive Silicon dioxide 2 wt%, Solid tribological properties. It was observed lubricant (NG &NTG 10 wt %).Tribo that addition of nano clay (≤2.25wt %) performance of both the friction enhances the hardness, impact strength, composites were evaluated by full scale storage, and loss modulus characteristics inertia dynamometer. It was observed that of the friction composites. The composite TGC proved superior performance in with minimum content of nanoclay terms of physical, mechanical, fade and (≤2.25wt %) exhibits highest friction wear properties .NGC on the other hand stability as well as variability coefficient; proved superior to NGC in recovery where as composites with higher content performance. Therefore, TGC can be of nano clay (≈ 2.75wt %) exhibits successfully used in friction materials to moderate level of stability coefficient and improve thermal conductivity, fade minimum variability coefficient. Fade performance, more lubricity and wear performance improves with the addition of reducing tendency of the composite in nano clay where as friction fluctuations copper less friction formulations. also increase continuously as the nano clay J.Wahstrom, D.Gventsadze [38] content increases. The wear performance investigated on novel nonporous decreased with the increase in composite based and conventional brake lapinus/nano clay; on the other hand it pad materials focusing on airborne wear increases by increasing aramid/graphite particles. Wear particles originating from composition in the friction composites. disc brake contribute to particulate concentration in the urban atmosphere. In A.R.Mat Lazim, M.Kchaou [40] Studied this work novel nonporous composite about Squealing characteristics of worn based and conventional brake materials brake pads due to silica sand embedment were tested against cast iron discs in a pin in to their friction layers. In this work, on disc machine. In these pads, nano pores three different sizes of silica Sand is (200-500 nm) are introduced in to the introduced between brake pad and disc friction material using diatomite particles. interface. Surface topography with and Copper, barites, and plasticizer are also act without Silica sand is examined and as ingredients of the friction material. A friction, squeal generated at the interface is modified phenol-formaldehyde resin is measured. It was observed that, with the

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inclusion of silica sand particles, new flat (MoS3, Sb2S3, as well as sulphides of Cu, area is observed and squeal occurrence Sn, Sb, and brass), fire proofing depends on silica sand particle size. Higher substances, and aluminum hydroxides to size of Silica sand particles damages the protect the pad from fire .It was observed pad surface and decreases the coefficient that the brake drum and brake shoe of friction. Optimum selection of SSP size interface temperatures with all composite is necessary to reduce the squeal material brake drum are lower than cast generation between disc and pad interface. iron brake drums. However, it was also Mohammad Asif [41] evaluated the observed that heat treated composite Tribological properties of aluminum based material brake drums had higher interface metal matrix composites used for temperatures as compared to that obtained automobile applications. In this paper Al with other Al-SiC MMC brake drums. The based metal matrix composites are used to Coefficient of friction with SiC particles in replace resin based brake pad. Two types the aluminum alloy shows higher values. of formulations FA101 & FA 102 is Telang A K, Rehman [43] studied about prepared by varying Sic & Graphite alternate materials in automobile brake content and keeping the remaining disc applications with emphasis on Al- compositions as equal. Brake pad Composites a technical review .In this formulation consists of Al (100 μm work grey cast iron rotor is replaced with 78.35wt% ), Sic ( for FA101 , 200 μm AMCs and its friction coefficient and 8.45 wt% for FA102 , 6.45wt%), Sb2S3 thermal conductivity is compared. It was (40μm 2 wt%) ,BaSo4(40μm ,3 wt%), observed that, the friction coefficient of Zinc(50 μm ,3 wt%) , Graphite (for FA101 AMC is 25-30% times that of cast iron 50μm 9.55wt% for FA102 7.54 wt%) rotor and exhibited better wear properties. .Wear behavior for brake pad was The thermal conductivity of AMC can be observed by krauss type of testing two or three times higher than Cast iron. machine. It was observed that Al based AMC is 60% lighter than gray cast iron composite possess less wear rate, same and having high thermal diffusivity around order of coefficient of friction as in resin four times greater than cast iron. Mukesh based bonded brake pads. Fluctuations in Kumar, Jayashree Bijwe [44] studied coefficient of friction are slightly higher in about Composite friction materials based comparison to resin. on metallic fillers Sensitivity of coefficient A.Rehman, S.Das [42] carried out an of friction (µ) to operating variables. In analysis on stir die cast Al-SiC Composite this work, the sensitivity of µ towards brake drums based on coefficient of braking pressure and sliding speed for friction. In this work at attempt is made to various metallic fillers i.e. brass, copper replace cast iron brake drums with and iron studied. It was observed that, aluminum silicon carbide composite brake copper powder is very effective in drum. Al-Sic MMC was reinforced with reducing µ sensitivity to dynamic 10% wt and 15%wt SiC particles. The variations in pressure and speed. Rongping effect of heat treatment of the Al-SiC Yun, Peter Filip[45] Evaluated the MMC brake drum was also studied. performance of eco friendly brake friction Performance was mainly evaluated on the materials .In this work, eco- friendly brake basis of brake drum coefficient of friction. friction materials were formulated without Friction material was developed with the copper, lead , tin, antimony trisulphide following components such as, binder, and whisker materials, to minimize their reinforcing Elements, fibers, abrasive potential negative environmental impacts elements (SiO2, Al2O3), filler elements on atmosphere. Friction material is (BaSO4, CaCO3, Al2O3), lubricants formulated with the following constituents

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namely, binder (Phenolic resin 36.5 wt%, It was also observed that friction material NBR (8.5 wt %)), fillers (Baryte 6.6 wt%, containing BaSo4 as an inclusion shows vermiculite (3.5 wt %)), friction modifiers the exactly opposite behavior. (Synthetic graphite 4.8wt%, resilient graphite carbon 5.3 wt% , Coke14.2 wt%, Vlastimil Matejka, Yafei Lu [47] molybdenum disulphide MOS2 0.4 wt% performed an experiment on the effect of ,antimony trisulphide Sb2S3 0 wt% , MgO Silicon carbide particle sizes on friction 3.3wt%,Potassium titanate 6wt%, Alumina and wear properties of friction composites Al2O3,4wt%,ZirconiumSilicate(ZrSiO4) designed for car brake lining applications. 0.9wt %) and reinforcements as (aramid In this study, a method is proposed for pulp 0 wt%, natural fiber 6 wt%, Metals increasing the friction characteristics of 0 wt %). The contents of binder and fillers friction material by inclusion of Sic are maintained constant, and the remaining particles of different sizes (3.4, 5.6, 9, 14.6 constituents are varied in proportions. Four vol %).The friction material with five samples are prepared on the basis of cost different compositions is formulated with estimation. It was observed that the sample the following ingredients namely A with above compositions exhibits stable Potassium titanate, wollastonite, Aramid coefficient of friction, effectiveness, high pulp, Brass chips, BaSo4, NBR, PF, Sic. fade resistance, good recovery capacity The highest value of coefficient of friction and low sensitivity to speed than other and lowest fade was observed with Sic 3 compositions. µm of size. The value of specific wear rate decreases with increasing Sic particle size. Mukesh Kumar, Jayashree Bijwe [46] Nandan Dadkar, Bharat S.Tomar [48] Studied about non asbestos organic (NAO) studied the influence of fly ash filled and friction materials with various metal aramid fiber reinforced hybrid polymer powders. In this work friction material was matrix composites (PMC) for friction developed with parental composition 90 braking applications .The friction-fade and wt% and fillers with 10 wt%. Three friction-recovery behavior has been different friction materials were evaluated as a function of temperature rise formulated by varying filler materials such at the disk brake interphase. In this work, as brass powder, Cu powder and Iron four samples of friction material was Powder. The parental composition of the developed with the following ingredients friction material consists of following namely, fly ash wt%(80,75,70,65) and ingredients: binder (Phenolic) 10 wt% , novalc resin wt%(20,25,30,35),aramid fibers (Aramid , Rock wool , Ceramic fiber 5wt% is added to 95 wt% of fly ash ,acrylic, Potassium titanate ) 23 wt%, for strength enhancement and four samples additives (graphite, alumina) 12 wt% and, are prepared. It was observed that the fade fillers (NBR Powder, Cashew dust, behavior has been observed to be highly Vermiculite ,barite) 45wt%. One dependent on the weight fraction of resin. composite friction material was fabricated The frictional fluctuations are observed to without using any metallic filler material be decrease with decrease in fly ash and compared with the three fabricated content. A higher recovery response is composites with metallic filler material as registered when the fly ash content is 80 Iron powder, Brass and Cu powder. For wt%. The analysis of friction performance tribo evaluation, inertia brake has revealed that the fade and static dynamometer testing was used. It was friction response are the major concluded that copper containing determinants of overall frictional response. composite showed increase in fade Wear analysis has revealed that material resistance and decrease in wear resistance.

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integrity and temperature rise of the disc rotor with titanium alloy rotor, which decides the wear behavior. weighs approximately 37% less than a cast S.Anoop, S.Natarajan. [49] Analyzed the iron rotor with the same dimensions. The factors influencing dry sliding wear tests are conducted for a flat block of behavior of Al/ Sic brake pad tribo system. different pad shape presses against a brake In this paper the composite material for rotor, consisting of repetitive on-and-off brake disc investigation was developed by drags at sliding speeds from 2 to 15 m/s, conventional liquid casting route from Al using nominal contact pressure of 1.0 or 6082 alloy by incorporating 15% Sic by 2.0MPa. Friction coefficients and weight. The design of experiments was temperature rise data were obtained for done based on surface response method. gray cast iron rotor and two commercial Ti The factors selected for investigation are alloys. Four experimental Ti based hard temperature, load and sliding velocity particle composites (10TiC, 5TiB, WTiC, keeping sliding distance as constant. It was 30TiB) and a thermally spray coated Ti observed that, with the increase of alloy (ThSp), Two Ti structural alloys, temperature the wear rate is found to be Ti64 and Ti6242, are formulated and severe. At lower loads, the wear rate was tested using brake dynamometer. It was found to be very less. At room temperature observed that, friction coefficient the effect of velocity is negligible but at decreases with increasing sliding speed higher temperature the wear rate increases and temperature for Ti alloy composites. with increasing in velocity. Keun Hyung At 2m/s, the friction coefficients are well Cho, Min Hyung Cho [50] investigated the within the normal range for brakes, but at tribological characteristics of brake 6 m/s and higher, they were at the lower friction material containing different end of the acceptable range. It was shapes of potassium titanate. In this work, observed that under the current set of the friction material is formulated with the friction testing conditions, gray cast iron following ingredients, aramid pulp, rock discs had better wear resistance than those wool(11wt%), Potassium titanate (20 wt%) made of Ti alloys and composites. ,Phenolicresin(16wt%),graphite,MoS2,Sb2 However, adding hard particles to a Ti S3(8wt%),ZrSiO4,MgO,Fe3O4(7wt%),Cash based composite can substantially improve ew, rubber, Cu Chips,Ca(OH2),(24wt%) its wear resistance. The highest value of vermiculite, BaSO4 (14Wt%) .Potassium friction coefficient was measured for the titanate is varied in the shapes of whiskers, thermally sprayed coating on Ti and the platelets and splinters. It was observed lowest for cast iron. (0.35-0.55).Finally, it that, the morphology of potassium titanate was observed that the thermally spray plays an important role in the formation of coated Ti alloy discs exhibits good contact plateaus and transfer films on the frictional performance and very low wear rubbing surfaces. The friction material and excellent resistance to fade. Jonathan with splinter shape potassium titanate N. Coleman, Umar Khan. [52] Reviewed shows better friction stability and on mechanical properties of carbon nano improved wear resistance compared to tube polymer composites. The mechanical those containing platelet or whisker due to properties of carbon nano tube make them larger contact plateaus and stable friction the filler material of choice for current films at the sliding interface. composite industry. Different processing methods have been formulated to improve Peter J.Blau, Brian C.Jolly [51] strength and toughness. It was observed investigated on titanium based materials that, there has been much progress has for brakes. In this work, an attempt is been made over the last few years in made to replace conventional cast iron composite industry to use carbon nano

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tubes as reinforcement. In future, CNT act friction and wear properties. It was as most important reinforcement in all the observed that the optimum wear behavior fields of application. was obtained in the samples pressed for 350MPa and sintered at 8200C. The K.W.Hee, P.Filip [53] evaluated the hardness of the bronze based specimen performance of ceramic enhanced phenolic increased by 100 % due to work hardening matrix brake lining materials for occurs during wear test. However, automotive brake linings. The friction and hardness of the Al2O3 added specimens wear characteristics of the composited did not show any considerable change in using t without potassium titanate and with hardness values. The highest friction potassium titanate sample are tested using coefficient was obtained in the samples a dynamometer. Two friction composite containing Al2O3 in the range of 4% due materials were prepared containing several to an increase in the temperature during ceramic materials embedded in a phenolic friction. It was observed that the addition Resin matrix. The first material sample (A) of 2% Al2O3 to the samples showed stable contains 25 wt% of fly ash and 14 wt% friction coefficient. The highest wear was additional ingredients namely( phenolic obtained in the sample containing no resin, styrene butadiene rubber 25 wt%), Al2O3 and the wear resistance of the barites 9 wt%, reinforcements( Twaron, samples increase with increase in the steel fiber, pulverized mineral fiber, frax amount of ZrSiO4. Yiqun Liu, Zhongqing fiber, copper chips, Iron powder, fly ash) Fan [55] Studied about application of nano 47wt% , friction modifiers (asbury powdered rubber in friction materials. In graphite, antimony tri sulphide, Coke, this work, an attempt is made to replace potassium titanate, magnesium oxide)19 ordinary styrene butadiene rubber and wt%. The second sample (B) is formulated nitrile butadiene rubber with nano rubber by adding potassium titanate, and having powder for manufacturing clutch facings same above ingredients in the following and disc brake pads. Dynamometer test rig percentages (20%, 9%, 47% & 24%). It is used to evaluate the test results and was observed that sample B and C, compared with respect to the ordinary containing less metal, exhibited lower and rubber powder friction materials. The more stable friction coefficients. Fly ash results showed that nano powder rubber by product can be effectively used in brake inclusion in the brake pads improves all lining formulations when properly the performance parameters and can be combined with other additives. The successfully used in the manufacturing of experimental results show that the friction materials. K.Laden, J.D. Guerin potassium titanate inclusion improves [56] investigated about frictional friction stability, wear improvement and characteristics of Al-SiC Composite brake fade reduction for the entire composite. discs. In this work, the use of light Mustafa Boz, Adem Kurt [54] has studied materials such as aluminum matrix the effect of Al2O3 on the friction composite reinforced with SiC in railway performance of automotive brake friction braking devices is studied. Continuous materials. This study consists of two braking tests were run with organic brake stages. In the first stage, bronze based pads in a dry environment. It was observed brake linings were produced and tested for that 390 matrix disc exhibited high wear friction and wear properties. In the second resistance compared with 514 matrix disc. stage, 0.5%, 1%, 2%, and 4% alumina It was also observed that, by increasing the Al2O3 powders were added to the bronze reinforcement rate by 8 wt% and based powders and Al2O3 reinforced spherical Sic, instead of angular one bronze based samples are evaluated for improves the wear resistance, braking

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power and high coefficient of friction for metallic friction material exhibits more the brake disc system. uniform friction layer on the surface. It Ho Jang, Seong Jin Kim [57] studied the was also observed that, with the increase effect of antimony trisulphide (Sb2S3) and in normal force the friction layer of NAO Zirconium silicate (ZrSiO4) in the friction composite increases on the disc automotive brake friction material on surface where as for semi metallic friction friction characteristics. In this work, materials tend to remove the friction layer Friction characteristics of nine automotive on the surface. Ashish .D. Dhangar, brake friction materials containing Prof.R.J.Jani. [59] Reviewed on wear different amounts of antimony trisulphide measurement of automotive disc brake (Sb2S3) and Zirconium silicate (ZrSiO4) friction material. Automobile brake system were investigated using a brake effectiveness is mainly measured by the dynamometer. Friction material is performance, wear, noise and durability. formulated with the following .The materials used in the test are non compositions , Phenolic Resin (20 wt%) , asbestos organic and semi metallic brake aramid pulp (6wt%) ,Ceramic fiber( pads sliding against a gray cast iron rotor. 3wt%) , Copper fiber (3wt%) , barium It was observed that the temperature sulphate (20wt%) ,Calcium hydroxide (3 generated at the contact region influences wt%) , molybdenum disulphide (3wt%) , the efficiency of the brake disc. Therefore, graphite (5wt%) , Cashew particles ceramic discs have highest tendency to (10wt%) , vermiculite ( 3 wt%) , rubber convert available frictional energy to particles (3wt%) , mica(3w % , Sb2S3 (2-6 dissipate to the surroundings and can be wt%), ZrSiO4(2-6 wt%),potassium titanate successfully used as a brake disc material (balance). It was observed that inclusion of for automobile applications. Sb2S3 improves the stability of friction coefficient. This appears to be due to the Bulent Ozturk, Sultan Ozturk [60] formation of antimony oxides at elevated studied the effect of resin type and fiber temperatures and the oxides play a role as length on the mechanical and tribological a lubricant at elevated temperatures. properties of brake friction materials. Torque variation during drag test is Three types of resins i.e. straight phenolic strongly affected by ZrSiO4 in the friction resin (SR), cashew nut shell liquid material, indicating that removable of modified resin (CR), and melamine resin friction film is undesirable in reducing (MR) is studied. Brake friction material torque variation. Friction stability is was formulated with the following improved by adding more Sb2S3 in the ingredients, lapinus fiber(23wt%) having friction material. length(150,300,650µm) , resin(16wt%) , barite(32wt%),Kevlar(7wt%),graphite(8wt L.Y.Barros, P.D.Neis [58] studied about %), Al2O3 , bronze, mica(14wt%). All morphological analysis of pad disc system mechanical, physical and tribological during braking operations .In this paper, properties of all composites were the amount of friction layer generated investigated. The results showed that both between the contact regions of disc surface resin type and fiber length played an is studied in detail. Two types of brake important role on the mechanical and pads NAO and Semi metallic were tribological properties of the friction subjected to slide against a gray cast iron materials. The highest and lowest friction disc under normal forces of 600N and coefficients for resin types were observed 1200 N. It was observed that both the for SR and MR Composites. , while MR friction materials form heterogeneous and CR composites showed the highest friction layer on the surface. But semi and lowest wear resistance. The wear

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resistance of the composite increases with conventional brake pad materials focusing increasing fiber length. The friction on air borne wear particles. Wear particles coefficient and specific wear rate of the originating from the disc brakes develop composites generally decreases with particulates particularly in the urban increasing fiber length regardless of resin atmosphere. In this work novel nano types. Yun Cheol Kim, Min Hyung Cho porous composite based materials and [61] studied the effect of phenolic resin, conventional brake materials are tested potassium titanate, and CNSL on the against cast iron disc in a modified pin on tribological properties of brake friction disc machine. It was observed that two of materials. In this study friction material the nano porous materials generated 3-7 was formulated with the ingredients times less airborne wear particles than namely fiber consisting (aramid pulp conventional materials. All tested vol8% , rock wool vol 8% , potassium materials exhibits wear particles of titanate vol 16 % ) ,phenolic resin vol 16 diameters approximately 350 and 550 nm. % , lubricants (graphite vol 3% , MOS2 Rukiye Ertan, Nurettin yavuz [64] studied Vol 3%), abrasives (zirconium silicate vol the effect of manufacturing parameters on 3%), friction modifiers (cashew vol 16 %, the tribological properties of brake lining others vol 27%).Tribological properties of materials. In this study, a brake lining non asbestos organic type formulation for composition was investigated on seven different formulations are evaluated experimental basis to observe the effect of using pin on disc tribo meter. It was the manufacturing parameters on observed that phenolic resin increased the tribological properties and obtain optimum coefficient of friction and observed high manufacturing considerations. The friction noise during sliding. The noise occurrence tests were performed using a chase type was reduced by increasing CNSL in the friction tester to find out the relationship friction material. Wear resistance of the between manufacturing considerations and friction material showed good results with tribological properties. The results indicate the addition of phenolic resin where as that no systematic relationship exists CNSL and potassium titanate deteriorated between roughness measured after the the wear resistance. P.V.Gurunath, J.Bijwe friction test and the manufacturing [62] developed a resin for brake pad parameters of brake lining. Under constant materials. In this work, a monomer heat treatment parameters, molding capable of polymerizing through ring pressure and temperature influence the opening by thermal activation was tribological characteristics of composites. synthesized in the laboratory and used as a As the molding time increased, the binder for friction composite. Two types of tribological characteristics improved non asbestos organic (NAO) friction remarkably. But, if the moulding time composites with identical ingredients but continues to increase then, tribological differing in the type of resin (10wt %) characteristics changes slightly. The were developed and tested for tribo molding temperature should be held within performance properties. It was observed optimum limits. It was observed that, that composite with new resin proved stability of the COF decreased better than composite with traditional considerably, and the specific wear rate phenolic resin in all performance increased at high molding temperatures. properties including µ, fade µ, disc The heat treatment temperature has a temperature rise, wear etc. negative effect on the COF and wear rate J.Wahlstrom, D.Gventsadze [63] studied at higher values. about a pin on disc investigation of novel nano porous composite based and

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Yu shu, Chen Jie [65] studied about the lubrication. It was also observed that effect of braking speeds on the tribological spraying water eliminate the establishment properties of carbon/Carbon Composites. of transfer layer at the friction inter phase. In this paper three types of micro From the wet friction and wear results it structures samples rough lamina, (Sample was revealed that, highest friction A), Smooth lamina, (SampleB), Smooth coefficient was exhibited by NF2 at all lamina, (SampleC), is tested using a pressures and speeds. Mean while NF1 laboratory brake dynamometer. It was showed best wear performance compared observed that, Sample A reached a peak to all formulations. Frction material value and exhibited good coefficient of behavior is entirely depend up on friction with increasing speed, compared atmospheric conditions. W. Osterle, H. to sample B and C. The weight losses in Klob [68] Studied about a better all of the samples were observed to understanding of brake friction materials. increase with increasing braking speed. This work mainly focuses on surface The oxidation abrasion at 30 m/s is less changes induced by repeated brake than that of 28 m/s for all the samples due applications and tries to provide to the low bond energy between the explanations about how such material graphite layers. M.A.Mlaeque, S.Dyuti modifications might affect friction and [66] carried out a material selection wear properties. Surface films were method in design of automotive brake disc. investigated by TEM. Two low metal In this paper an alternative material to pads A-1 having mass ( Rubber 1% , replace gray cast iron rotor has been Resin 7% , Fibers 3% , Metals 38%, studied. Gray cast iron rotor material is Fillers 23% , Lubricants 13% , Carbon widely used in automobiles and consumes 15% ) and A-2 having mass ( Rubber 2%, more fuel due to its high specific gravity. Resin 7%, Metals 39% , Fillers 20%, A method is proposed to study alternative Lubricants18%, Carbon12%) is fabricated materials like aluminum alloy, titanium and tested on brake discs. Two important alloy, ceramic composites to replace gray characteristics were observed both on the cast iron rotor. It was observed from the pad and disc surface, namely steel results that Al matrix composite exhibits constituent, either ferritic pad or pearlitic better mechanical properties including disc. It was observed that coefficient of compressive strength, wear resistance, friction of 0.35 and 0.85 was observed for thermal conductivity, and specific gravity oxide on oxide and metal on metal than other combinations. N.S.M. El-Tayeb, contacts for automata of size 10 nm. K.W.Liew. [67] Studied about the effect of R.K.Uyyuru, M.K.Surappa [69] studied water spray on friction and wear behavior the effect of reinforcement volume fraction of non commercial and commercial brake and size distribution on the tribological pad materials. In this paper the reduction behavior of Al composite .In this work, in friction coefficient during rainy season brake pad material was used as pins while and humidity environment is taken as a the AMC is used as rotating disc. Load and serious problem as it results no safety to sliding speeds were varied over a range to vehicle. Four types of friction material represent actual braking conditions in (NF1, NF2, NF4, and NF 5) and two passenger cars. Effect of volume fraction commercially available brake pads (CMA and size distribution of reinforcement on and CMB) were developed and tested by wear and friction coefficient has been using a small scale tribo tester. It was studied. It was observed that wear rate and observed that the friction coefficient for friction coefficient vary with both the the sample NF1 & NF4 were less than 0.05 applied normal load and the sliding speed. which was in the range of friction in mixed The Wear rate increases with increase in

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normal load, Wear rate decreases with lower friction coefficients of MMC’s. increase in sliding speed, friction V.M.Kryachek. [72] reviewed on sintered coefficient decreases with increase in metals and alloys. In this work, production normal load and friction coefficient and testing of powder materials based on decreases with increase in the sliding copper and iron powder are discussed and speed. The harder tribo layer formation act their applications are demonstrated and as a lubricant layer and acting as a source new methods for forming friction and of wear debris. M.Kermc, M.Kalin [70] coatings on them are analyzed. developed an apparatus for tribological S.Ramaousse, J.W.Hoj [73] studied about evaluation of ceramic based brake thermal characterization of brake Pads. In materials. In this paper the behavior of this paper the chemical and physical brake disc made of gray cast iron and decomposition processes that occur in a carbon/ceramic SiC matrix are compared. brake pad heated to 10000 C have been The size of the samples was determined on studied. Thermo gravimetric analysis, the basis of vehicle’s speed of (0-300 differential thermal analysis, used in Km/h), contact pressure (0.1 to 10 MPa), combination with gas analysis and image and the temperature (20 0 C to 900 0 C). analysis using SEM is performed. Brake The temperatures generated at the contacts pad consists of iron, carbon, and binder. It of ceramic carbon composite is high at was observed that the decomposition of 8000C ,which is more than two times the binder system takes place between 250 higher than conventional gray cast iron and 4750C. The oxidation of the coal .The coefficient of friction at the contact occurs in two steps. The first oxidation region for ceramic carbon composite C/C starts at around 300 0 C and ends at around Sic was observed to be above 0.5 and two 475 0 C. The second oxidation of the coal times higher than gray cast iron. takes place between 525 and 700 0 C. The Therefore, depending up on the coefficient oxidation of the graphite takes place of friction and temperatures generated at between 600 and 850 0 C .The oxidation of the contact plateaus, a proper material is the iron starts at around 500 and continues selected for the design. slowly up to 800 0 C. Mikael Eriksson , Staffan Jacobson [74] Studied about K.M.Shorowordi, A.S.M.A.Hasseb [71] tribological surfaces of organic brake pads. studied the velocity effects on the wear, In this paper the tribological contact friction and tribochemistry of aluminum situation of organic brake pads against metal matrix composites (MMC) sliding gray cast iron disc is studied on a against phenolic brake pad. Two (MMC) microscopic level. when organic brake reinforced with 13 Vol% SiC or B4C pads worn against rotor, the complex particles were made by stir casting structure and inhomogeneous formation of followed by hot extrusion. Effects of the brake pads results in formation of large sliding velocity on the friction, wear, and contact plateaus of few micrometer size tribochemistry of the worn surfaces of above the surface. In this work, Organic both composites sliding against a brake pad is formulated with the following commercial phenolic brake pad have been ingredients of fibers ( Steel, Aramid, and investigated under dry condition. The wear glass fibers) 30 wt% , binder 8 wt%, others tests were carried out using a pin on disc 11 wt% , friction modifiers ( brass and type apparatus at two linear sliding speeds, bronze 15 wt% ,graphite 15 wt% , metal 1.62 and 4.17 m/s under a constant sulphides 8wt % , abrasives quartz 5 wt %, pressure of 0.75MPa for a sliding distance fillers Clay and iron oxide 8 wt % . It was of 5832 m. It was observed that higher observed that with increasing pressure, the sliding velocity leads to low wear rate and plateaus will be slightly smaller than the

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equilibrium size at the contact pressure. softened and charred to loose its bonding This results in slightly lower coefficient of strength. The reinforced fibers are then friction than during decreasing pressure. pulled and escaped from the matrix, and When comparing two pad materials, the friction films are formed on the friction one that showed the more pronounced surface. Second, the friction films will be plateau growth with increasing pressure deformed, cracked and peeled to form also showed the good coefficient of small debris which decreases the friction friction. stability, increases the wear, and sometimes even causes severe vibration From the work carried out by many and noise. It was observed that, further researchers on filler materials, it was increase of surface temperature leads to observed that, selection of filler materials thermal decomposition of friction material plays a prominent role to improve the ease and fading phenomenon will occur and of manufacturing of the friction composite. friction coefficient will decrease. Besides The filler material inclusion is responsible having thermal decomposition, organic for improvement of wear rate and friction material will release gases to stabilizing the coefficient of friction of the generate gas cushion films, which weakens composite. It depends mainly on the speed the coefficient of friction to great extent. of the vehicle and operating temperatures OZturk et al [89]. Studied the influence of at the contact region of the brake disc. temperature on friction and wear behavior Based on these parameters, one has to of four different friction materials. Four select proper filler material for a required different reinforced fibers are used in this application. study namely, ceramic fiber, rock wool fiber, glass fiber and steel wool fiber. It 2.3 Influence of temperature, pressure was observed that four different friction and speed on friction and wear materials have similar influence on Braking phenomena involves transfer of temperature. Fig2.3 (a) shows the behavior kinetic energy to heat energy. The of ceramic fiber with increase of frictional heat generated at the contact temperature. It can be seen that friction region will affect the wear and friction coefficient increases with temperature at coefficient of the friction material. By first but starts to decline when the increase of braking pressure and initial temperature reaches at 3000 C. However braking speed, the friction temperature the wear rate increase with increase of generated at the contact region will temperature and become serious at higher increase. First the matrix resin will be temperatures.

Fig 2.3(a) Influence of temperature on friction and wear of organic friction material

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The braking pressure acting on the interface are defrormed and broken to component affects the friction and wear form some debris. when the braking behavior of friction materials.The pressure is further increased , more debris approach of pressure on friction material is will form on the surface of friction classified by four types . First, changing material, which leads to formation of the actual contact area of frction pair. granular films.The friction film act as second ,affecting the generation of friction lubrication film on the interface , which films .third influencing the component and reduces the meshing force to decrease the oraganisation of friction material , and friction coefficient. Fom Fig2.3(b) , it is fourth,changing the wear type. Among the observed that the friction coefficient above mentioned , the first two types are increases first and then decreases with generally considered as the most important increase of pressure.However, the wear factors. By increase of braking pressure , rate keeps increasing with increase of the asperities distributed on the contact pressure.

Fig 2.3(b) Influence of Pressure on friction and wear of organic friction material.

As the actual contact area of friction pair is the speed reaches a certain value, the much lower than its nominal contact area, friction coefficient decreases slowly and the direct influence of initial braking speed finally remains steady, while the wear rate on the friction behavior can be ignored. increases continuously with the increasing From Fig 2.3(c), it was observed that, initial braking speed. It has slower with increase in initial braking speed, the increasing rate of wear at medium braking friction coefficient increases first. After speed.

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Fig 2.3(c) Influence of initial braking speed on friction and wear of organic friction material

2.4 Effect of modeling and simulation with pad is modeled and characterized for techniques on friction and wear mechanical properties and simulation was Many people have studied the behavior of carried out for baking time of t=45s and friction materials performance by using results are plotted for increment of initial experimental techniques like inertia brake time for 0.125s,0.25 s, and 0.5 sec dynamometer test rig. Now days, modeling respectively. Tensile, compressive and and simulation techniques are widely used shear stresses induced in the disc for before design, because of ease of doing various types of mesh sizes and influence analysis, less time and cost effective. of modulus of elasticity of the pad material Simulation techniques help to predict the and rotational speed, friction coefficient is behavior and factor of safety to be studied in detail. It was observed that gray assigned for the component before design cast iron disc produce better mechanical phase, which makes easier for the designer behavior and the presence of groove in the to assess the performance of friction pad negatively affects the mechanical material before manufacturing. behavior of the brake pad. A. Renault, F.Massa. [77] Investigated on brake squeal X C Wang, J.L.Mo [75] Studied on Squeal analysis and observed that, pad topography noise of friction material with groove and contact distribution plays an important textured surface, using experimental and role in the design of braking system. numerical analysis by varying the pad Vikrant J. Kotwade, H.P Khairnar [78] profile. It was concluded that cutting a135 Reviewed on brake Squeal and observed deg groove can reduce unstable vibration that, holographic interferometry and and cutting a 45 deg or 90 deg groove on numerical methods like finite element the pad surface shows a reduced squeal analysis using ANSYS plays an important generation. It was also observed that, the role to eliminate brake squeal in design maximum contact pressure is low for the stage. Swapnil R. Abhang, D.P.Bhaskar 90 deg groove textured surface, followed [79] Studied about design and analysis of a by the 45 deg groove texture surface. A. disc brake to replace existing gray cast Renault, F.Massa. Ali Belhocine, Wan iron disc material. From the thermal and Zaidi Wan omar [76] performed a modal analysis results, carbon ceramic numerical parametric study of mechanical matrix composite disc achieved good behavior of dry contact slipping on the braking performance. Amr M. Rabia, disc pads interface. In this work disc brake Nouby M. Ghazaly [80] Reviewed on

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experimental studies of automotive disc using composite friction materials brake noise and vibration and proved that containing Thermo plastic Elastomers the experimental data gives good results (TPEs). Thermo plastic elastomers are compared numerical solutions. Saeed Abu visco elastic polymeric materials which are Alyazeed Albatlan [81] investigated on the introduced in to the friction material in effect of pad shapes on temperature order to increase the damping behavior of distribution for disc brake contact surface. the cured friction material. In this work, Flat pad and hatched pad are tested using a Styrene butadiene styrene (SBC), Styrene brake dynamometer and concluded that, ethylene butylenes styrene (SEBS) and hatched pad perform better fade resistance nitrile rubber/ Poly vinyl chloride than the flat pad. A.Belocine, M. (NBR/PVC) blend systems were used as Bouchetara [82] studied about thermo TPE materials. Dynamic mechanical mechanical behavior of dry contacts in analyzer is used to evaluate viscoelastic disc brake rotor with gray cast iron parameters such as loss factor (tanγ) and Composition. Three types of cast iron storage modulus (E’) for the friction materials (AL FG 25, FG 20, and FG 15) material. Natural frequencies and mode are tested using ansys software. It was shapes of the friction material were observed that the temperature field determined by modal analysis. It was depends on the numerical and design observed that, NBR/PVC and SEBS parameters. Y.Yildiz and M.Duzgun [83] showed to be more effective in terms of Conducted a stress analysis on ventilated damping behavior, preventing resonance type disc brakes using the finite element and reducing noise squeal generation method for cross drilled disc, cross slotted between pad and the rotating disc. disc, and cross slotted with side groove O.O.Evtushenko, E.H.Ivanyk [87] disc .It was concluded that C-SG disc Reviewed on analytic methods for thermal showed best performance in terms of calculation of brakes. It was observed that, braking force output. M.Nouby, new applications of theory of heat K.Srinivasan [84] investigated on disc conduction and thermo elasticity can be brake squeal reduction through pad applied to solve dynamics of friction structural modifications using FEM using problems easily. complex eigen values. The geometric characteristics and chamfer would affect CONCLUSION the squeal propensity and eigen modes. Jinchun Huang, Charles M. Krousgrill [85] The future emphasis on automobiles will evaluated a critical value of coefficient of be lower emissions and fuel efficiency, as friction using brake squeal analysis. In environmental regulations become more order to reduce automobile brake squeal stringent. The brake friction material mode coupling analysis is performed. selected for the design and manufacturing Eigen values and Eigen vectors are should not release any toxic substances in calculated for different types of mode to the atmosphere. The dynamic behavior couplings to estimate critical value of of the friction material has to be studied in friction coefficient. A new method called detail to understand the behavior of reduced order characteristic equation is squealing action against the application of used to evaluate eigen values and their braking load. The bonding strength derivatives at µ=0.This method can be between fiber and matrix should be accurately applied to predict the stability improved in order to achieve good wear boundaries of brake. Mohsen Masoomi, resistance, fade resistance and mechanical Ali asghar katbab [86] studied about properties of the friction composite. reduction of noise from disc brake systems

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There is also need to develop a friction 8. M.A.Maleque, A.Atiqah. New Natural material by selecting a proper chemical fiber reinforced Aluminium composite treatment method on fiber to use more for automotive brake pad in effectively as reinforcement in polymer international journal of mechanical and matrix composites. There is also need to materials engineering (IJMME), vol7 , concentrate on the interfacial adhesion, 2012,166-170. and bonding strength between fiber and 9. N.Aranganathan, Vishal Mahale. matrix for a friction material to achieve Effect of aramid fiber concentration on better mechanical and tribological the friction and wear characteristics of properties. non asbestos organic friction composites using standardized braking REFERENCES tests. Science direct, Elsevier, wear 354-355, 2016, 69-77. 1. D Chan and G W Stachowiak. Review 10. Peng Cai, Zhenlian Li. Effect of aspect of automotive brake friction materials. ratios of aramid fiber on mechanical Proc. Instn Mech. Engrs, Vol218 part and tribological behaviors of friction D: J.Automobile Engineering 953-966. materials, Tribology international, 2. Barrett JC, Lamb PW and Wiseman Elsevier, 2015; 109-116. RW. Multiple mechanisms for the 11. T.Singh, A.Patnaik. Performance carcinogenic effects of asbestos and assessment of lapinus-aramid based other mineral fibers. Environ Health brake pad hybrid phenolic composites Persp 1989; 81-89. in friction braking. Science Direct, 3. Takashi kameda, Ken Takahashi Elsevier, 2014; ACME191; 1-11. Research in Asbestos use, bans and 12. Vivek Dhand, Garima Mittal Short diseases burden in Europe, volume 92, review on basalt fiber reinforced World health organization; 1-8. polymer composites, Composites: 4. Xingming xiao, Yan Yin “Review on PartB, Elsevier, 2015, 166-180. the friction and wear of brake 13. V.Fiore, T.Scalici, Review on basalt materials.” Review, Advances in fiber and its composites, Science mechanical engineering 2016, vol 8 direct, Elsevier, Composites part-B 74, (5), SAGE journal, 1-10. 2015, 74-94. 5. K.L.Pickering, M.G.Aruan Efendy, 14. Ashok Kumar Ilanko, Srinivasan T.M.Le. Review of Recent Vijayraghavan .wear behavior of developments in natural fiber asbestos free eco friendly composites composites and their mechanical for automobile brake materials, performance. Composites: Part A Friction 4(2), 2016, 144-152. Elsevier, 2016; 98-112. 15. B.K.Satapathy, J.Bijwe, Performance 6. Emad omrani, Pradeep L Menezes. of friction materials based on variation State of the art on tribological behavior in nature of organic fibers- Part-I Fade of polymer matrix composites and Recovery behavior. Elsevier, reinforced with natural fibers in the Wear, 2004, 573-584. green materials world, Elsevier, 16. Bhabani K.Satapathy, Jayashree Bijwe Science direct, engineering science and Composite friction material based on technology an international journal 19, organic fibers: Sensitivity of friction JESTECH, 2016, 717-736. and wear to operating variables. 7. Umar Nirmal, Jamil Hasim Review on Science direct, Elsevier, Composites tribological Performance of natural part A 37, 2006, 1557-1567. fiber polymeric composites. Tribology 17. A.P.Garshin, V.I.Kulik. A new international, Elsevier, 2015, 77-104. generation of construction materials

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