Search Results (34)

The paper offers an overview of the motor vehicle brake pad wear process. Considering the types of wear that occur between the pads and the disc, the study begins by presenting Archard’s fundamental wear law. It explains how the hardness and roughness of materials can influence the wear rate. Furthermore, the analysis describes factors influencing the wear coefficient, including chemical affinity between materials, surface quality, thermo-elastic instability (TEI) of the materials, and environmental effects. The paper also presents detection systems for brake pad wear, such as sensors-based monitoring and artificial neural networks (ANNs). These systems monitor brake pad wear in real time, thereby improving the driving safety by alerting the driver to the condition of the brake pads. The principles and systems analyzed form the basis for predictive maintenance, minimizing the risks of brake failure due to excessive wear. Full article

A plasma-assisted electrochemical deposition (PAECD) technology was introduced to coat a cast iron brake disc for the possible reduction of brake wear and brake wear particle (BWP) emission. The majority of the coating consisted of alumina (Al₂O₃), determined by energy dispersive X-ray (EDX) analysis and X-ray diffraction (XRD) analysis. To validate the above strategy of the coating technology for automotive brake corners, one brake stock rotor was replaced by a PAECD-coated rotor for a vehicle road test. After the road test, weight loss of the brake components (rotors and pads) was measured, showing that the alumina coating can reduce the brake wear by more than 70%. BWPs were also collected from wheel barrels, spokes, and brake friction rings of the coated and uncoated rotors during the road test. A morphology and chemical composition analysis of the collected BWPs indicated that the coating could reduce BWP generation from the original sources and avoid a metal pick-up (MPU) issue, leading to less metallic content in BWPs. This alumina coating may provide the auto sector with a sustainable approach to overcome the brake dust emission problem, evidenced by less wear of the brake pads, minimal wear of the coated brake rotor, less MPUs, and a clean wheel rim on the coated brake corner. Full article

During braking, high-power wind turbine disc brake friction pairs experience thermo-mechanical interactions at the interface, which lead to both physical and chemical changes. The friction interface features asperities and embedded hard particles within the substrate. Wear debris from these asperities or dislodged hard particles accumulates at the interface, continuing to participate in the friction process—a phenomenon known as the “endogenous third body”. Throughout braking, the microscopic morphology and contact conditions of the interface evolve dynamically. The stress–strain distribution and vibration behaviour of the friction system, influenced by the endogenous third body, also vary with braking parameters. This study employs the W-M fractal theory to develop a finite element model of a rough friction interface containing hard-particle endogenous third bodies. The model is validated through experimental testing. Based on the performance test parameters of high-power wind turbine disc brakes, a simulation is conducted to analyse the contact friction process involving the endogenous third body at the rough interface between the brake disc and brake pad. The simulation reproduces the formation process of the endogenous third body and reveals its evolutionary stages, including “ploughing”, “gap-filling”, and “aggregation”. Additionally, the study examines changes in the internal stress–strain and vibration states of the friction system under varying braking speeds (5 m/s to 35 m/s) and braking loads (3 MPa to 6 MPa). The findings demonstrate how different braking parameters influence the friction system containing the endogenous third body. The results showed that when the braking speeds were 5 m/s, 15 m/s, 25 m/s, and 35 m/s, and the braking load was 6 MPa, the average amplitude of the brake pads was the smallest, at 0.017 mm, 0.021 mm, 0.025 mm, and 0.020 mm, respectively. This research provides valuable insights into the three-body contact friction mechanism at the micro-braking interface, the formation of composite material third bodies, and the role of wear-stage third bodies in affecting the friction interface. Full article

The hard particles in the copper-based powder metallurgic material of a brake pad for a wind turbine brake falls off and presses into the surface of the brake disc to form abrasive particles under high-speed and heavy-load working conditions. The presence of abrasive particles will produce abrasive wear with micro-scratch and micro-scribe on the copper-based material of the brake pad. The critical scratch depth effect in the abrasive wear process is proposed based on the critical depth effect of the metal removal process at the micro-scale. The abrasive wear is divided into two types: scratch wear and scratch wear, which is proposed according to the comparison of the actual scratch depth and the critical scratch depth. The range of braking speeds and friction coefficients in abrasive wear is determined by the recommended parameters of the disc brake. The ABAQUS2020 software is used to simulate and analyze the micro-scale abrasive wear of a brake pad. The brake strain/stress curves of the brake pad under different brake speeds and friction coefficients are compared and analyzed for two abrasive wear types based on the range of braking parameters, and the key factors affecting abrasive wear are proposed. Full article

This research, focusing on the environmental impact of tire and brake disc pad wear, constitutes a significant area of transport-related studies. These two key vehicle components are not only the most frequently worn but also generate micro- and nano-pollutants (i.e., rubber, metal oxides) that potentially harm the environment. Over half of the globally produced natural and synthetic rubbers, which amounted to about 30 million tons in 2022, are used for tire production. This work focuses on the study of roadside snow, sand, and standing water deposits from various locations in the urban agglomeration (Poznań, Poland) during the winter season, determining their qualitative composition and the quantitative content of pollutants originating from tire abrasion. In addition, the method of washing nano- and micro-rubber particles and their full characteristics was also presented. Fourier-transform infrared (FT-IR) and nuclear magnetic resonance (NMR) spectroscopic studies, optical and scanning electron microscopy (SEM-EDS), particle size studies using a dynamic light scattering (DLS) particle analyzer, and thermogravimetric analysis (TGA) were conducted for a detailed characterization of the pollutants in the environment. The conducted particle separation methods allowed for the extraction of a fraction mainly containing gum residues with particle sizes less than 2 µm. The results of these tests make it possible to estimate the level of contamination with rubber and metal residues during the abrasion of tires, pads, and brake discs while driving, which is crucial for understanding the impact of vehicle part exploitation on the environment. Full article

The study of the tribological behavior of the braking system in auto vehicles requires knowing the characteristics of the material in contact and, in the work process, the friction pair brake disc pads. Material structural analysis is necessary because the wear process depends both on the friction-pair chemical composition (brake disc pads) and on the work process parameters (pressing force, rotational speed, traffic conditions, etc.). The material of the brake discs is generally the same, gray cast iron, and the brake pads can be semimetallic (particles of steel, copper, brass, and graphite, all united with a special resin), organic materials (particles of rubber, glass, and Kevlar, all joined with the help of a resin), composite materials that contain different constituents, and ceramic materials (rarely have small copper particles). Therefore, the purpose of this paper is to analyze the crystalline structure, tribological behavior (at friction and wear), and the mechanical properties of the materials of the brake disc–pad friction pair specific to the field through study and analysis. Full article

Brake wear particles are generated through frictional contact between the brake disc or brake drum and the brake pads. Some of these particles may be released into the atmosphere, contributing to airborne fine particulate matter (PM_2.5). In this study, an onboard system was developed and tested to measure brake wear particles emitted under real-world driving conditions. Brake wear particles were extracted from a fixed volume enclosure surrounding the pad and disc installed on the front wheel of a light-duty vehicle. Real-time data on size distribution, number concentration, PM_2.5 mass, and the contribution of semi-volatiles were obtained via a suite of instruments sub-sampling from the constant volume sampler (CVS) dilution tunnel. Repeat measurements of brake particles were obtained from a 42 min bespoke drive cycle on a chassis dynamometer, from on-road tests in an urban area, and from braking events on a test track. The results showed that particle emissions coincided with braking events, with mass emissions around 1 mg/km/brake during on-road driving. Particle number emissions of low volatility particles were between 2 and 5 × 10⁹ particles/km/brake. The highest emissions were observed under more aggressive braking. The project successfully developed a proof-of-principle measurement system for brake wear emissions from transient vehicle operation. The system shows good repeatability for stable particle metrics, such as non-volatile particle number (PN) from the solid particle counting system (SPCS), and allows for progression to a second phase of work where emissions differences between commercially available brake system components will be assessed. Full article

Iron (Fe), the main component of non-exhaust particulates, is known to have variable health effects that depend on the chemical species of iron. This study characterized the possible contribution of iron oxides and hydroxides to airborne brake wear particles under realistic vehicle driving and braking conditions with different brake pad friction materials. We found significant differences in wear factors and PM₁₀ and PM_2.5 emissions between non-asbestos organic (NAO) and European performance (ECE) brake pads. Iron was the dominant contributor to PM₁₀ and PM_2.5 brake wear particles for both NAO and ECE. The iron concentration ratio in the particle mass (PM) was comparable to the disc-to-pads ratio measured by wear mass. The fact that magnetite, which is of interest with respect to health effects, was less abundant in NAO than in ECE suggested that tribo-oxidations occurred in NAO. Metallic iron is generated not only from abrasive wear but also from tribo-chemical reduction with magnetite as the starting material. We found that there were differences in PM emissions between brake friction materials, and that the phase transformations of iron differed between friction materials. These differences were apparent in the distribution of iron oxides and hydroxides. Heat, tribo-oxidation, and tribo-reduction are intricately involved in these reactions. Full article

In this study, the potential of Fe₃Al coating material as an environmentally friendly alternative to coatings containing critical elements for brake discs was investigated. A buffer layer of Cr–Mo steel (Ferro 55) that was about 500 µm thick was applied on a gray cast iron disc to enhance the coating quality and prevent the formation of hot cracks during solidification. The microstructural analysis of the cross-section of the coating showed that the buffer layer diffused into the Fe₃Al coating, forming a combination of Fe₃Al, Fe, and Fe₃AlC_0.5 phases. The tribological properties of the Fe₃Al-coated disc were evaluated using pin-on-disc tests against two different copper-free friction materials extracted from commercial brake pads. The wear results show a coefficient of friction comparable to that of an uncoated disc (≈0.55), but with a reduction in particulate matter (PM) emissions, which decreased from 600 to 476 #/cm³. The last issue is an interesting aspect that is gaining increasing importance in view of the upcoming international standards. Full article

The growing number of vehicles leads to increasingly intense and congested traffic, which will additionally put demand on the braking system, and drivers behave more aggressively. As a result, the braking system must be durable and efficient. For this purpose, the study of the braking system behavior in conditions of intense and moderate traffic is required to increase the safety of traffic participants—respectively, to demonstrate the need for more frequent replacement of some braking system elements. Thus, a series of successive tests were performed on a vehicle, through which the degree of wear of the brake pads and discs was monitored periodically, resulting in the efficiency evolution of the braking system. The tests were carried out both in the laboratory (on a dynamometer) and in traffic to establish the efficiency of the braking system according to some parameters considered essential. The experimental tests showed that the recommendations regarding the frequency of replacement of brake pads and discs are inconsistent with their actual wear. Therefore, the aim of this paper is to establish the braking system efficiency of a vehicle, subject to testing depending on the vehicle mass, travel speed, distance driven, and braking time, based on experimental tests, on stand and in-traffic, according to the road safety regulations. The validation of the braking system efficiency of the tested vehicle was done by measuring the stopping distance and time in relation to the initial speed, the mass of the vehicle, the number of kilometers traveled, and conditions of intense and moderate traffic. Full article

Exhaust regulations and improved exhaust gas treatment systems have already initiated the trend that brings emissions from brakes and tires to the forefront of traffic-induced particulate matter. The health and environmental relevance of particulate matter has resulted in regulators, industry, and research institutions prioritising the mitigation of non-exhaust particle emissions. To this end, under the umbrella of the United Nations Economic Commission for Europe World Forum for Harmonisation of Vehicle Regulations (UNECE WP.29), the Working Party on Pollution and Energy (GRPE) mandated the Particle Measurement Programme Informal Working Group (PMP-IWG) to develop a Global Technical Regulation (GTR) for measuring brake dust. The standards and procedures defined within the GTR should eventually form the basis for the introduction of a Euro 7 limit value for brake emissions. The purpose of this measurement campaign is to provide an exemplary overview of the emission behaviour of wheel brakes and friction pairings currently available on the market and to identify possible reduction potential with regard to particulate emissions. All measurements were carried out taking into account the draft GTR valid at the time of execution. For the investigations, brakes were selected using the example of different vehicle classes, brake concepts (disc and drum brake), vehicle axles (front and rear axle), and alternative friction materials (brake disc and pads/shoes). Thus, the use of wear-resistant discs and improved brake pad compositions are able to achieve significantly lower emissions. In addition, the measurement of brake dust emissions from vehicles with different levels of electrification was considered. Electrical braking was modelled and applied to the Worldwide Harmonised Light-Duty Vehicles Test Procedure (WLTP) Brake Cycle, which has demonstrated high emission reduction potentials depending on the electrification level. Full article

The Particle Measurement Programme (PMP) informal working group co-ordinated a global interlaboratory study (ILS) on brake wear particle emissions with the participation of 16 laboratories in 2021. Two articles present the results of the ILS: (I) particulate matter mass (PM) and (II) particle number (PN) emissions. The test matrix covered different brake systems, including ECE and NAO pad materials with grey cast iron discs and a drum brake. Regarding PN, the study measured the total particle number from approximately 10 nm to 2.5 µm (TPN). Some testing facilities measured solid particle number emissions (SPN) in parallel. The mean TPN concentrations ranged from 9.1 × 10⁸ #/km/brake to 1.1 × 10¹⁰ #/km/brake. TPN and SPN emission levels were comparable, except for one lab that measured very high volatile particle emissions for one brake system. The minimum and maximum SPN emissions for a given brake differed by a factor of 2.5 ± 0.5, comparable to data from exhaust SPN ILS measurements. This article provides an overview of lessons learned and subsequent measures incorporated in an upcoming global technical regulation to reduce measurement variability when sampling and measuring brake particle emissions for light-duty vehicles up to 3.5 t. Full article

Brake-wear particle emissions are the result of the components of a friction brake being in tribological contact, and they are classified as non-exhaust emissions. Since most of the emitted particles belong to the size classes of particulate matter (≤10 μm) and differ significantly in terms of their physico-chemical properties from automotive exhaust emissions, this source is of particular relevance to human health and, therefore, the focus of scientific studies. Previous studies have shown that coated brake discs offer significant wear and emission reduction potential. Nevertheless, no studies are available that describe the specific particle formation process, the contact conditions, the structure of the friction layer and the differences compared to conventional grey cast iron discs. The aim of this study is to describe those differences. For this purpose, the tribological behaviour, the structure of the friction layer and the associated particle dynamics within the friction contact between a laser cladding coated disc and a conventional grey cast iron disc are compared. The required investigations are carried out both ex situ (stationary) and in situ (dynamic). Parallel to the tribological investigations, the particle emission behaviour is determined on an inertia dynamometer using a constant volume sampling system (CVS) and equipment for particle number and particle size distribution measurement. The results show that, for two different brake pads, the laser cladding brake disc has lower wear and less particulate emissions than the grey cast iron brake disc. The wear behaviour of the coating varies significantly for the two brake pads. By contrast, the grey cast iron brake disc shows a significantly lower influence. Full article

Brakes play an extremely important role in any vehicle. In today’s automotive industry, friction brakes are most often used, in which the composite material of the brake pad cooperates with a cast iron disc. While little can be modified in the case of discs, in the case of pads, the composition of the material used for its production can have an almost unlimited number of possibilities. Both scientists and manufacturers invent and test new combinations to achieve the desired end result. A similar task was undertaken in this work. Bearing in mind the fact that materials commonly used as reinforcing materials generate undesirable threats in the production process, it was decided to check whether this role could be taken over by another substance that is already present in brake pads; this substance is copper. A number of samples containing copper, in the form of powder and fibers, were made, and then the samples were subjected to tribological tests in order to determine the coefficient of friction and abrasive wear rate. The ball-cratering research method was used, and the Taguchi process optimization method was used to plan the experiment. As a result of the tests, it was found that the replacement of aramid fibers with copper fibers does not significantly affect the value of COF and the abrasive wear rate. Full article

Non-exhaust brake dust and pollution arising from metal, semi-metal, and ceramic brake pads have made recent research consider their replacement by potential natural fibers such as hemp, flax, sisal, etc. These natural fibers are lightweight, biodegradable, and cheap. This paper discusses the wear and friction analysis of hemp fiber reinforced polymer brake pad material. Three test specimens viz. HF4P20, HF5P20, and HF6P20 were prepared per ASTM G99 standards for the pin-on disc tribo-test. The test trials and validation were done using the Taguchi design of experiments and ANOVA. The optimum result showed a consistent coefficient of friction and lowered specific wear rate for HF6P20 brake pad material. Worn surface morphology was done using scanning electron microscopy. Full article