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Trib Ology Compressed
www.elsevier.com/locate/triboint
Received 23 February 2015; received in revised form 23 October 2016; accepted 1 November 2016
Abstract
Experimental studies of friction characteristics were conducted using gray cast iron and automotive brake linings. The gray iron
samples were manufactured to have different microstructures by changing the carbon equivalent and cooling speeds of melts and
two different types of non-commercial brake linings (non-steel and steel-containing linings) were used as a counter material. Friction
tests were performed on a pad-on-disk type tribotester and particular emphases were given to the effect of graphite flakes and
ferrite in the gray iron disks on fade phenomena and the level of the coefficient of friction. Resul ts showed that the coefficient of
friction increased with the amount of graphite flakes on the gray iron and the effect was more pronounced in the case of usin g steel-
containing linings. The amount of ferrite phase on the disk surface showed little influen ce on the coefficient of friction. Fade
resistance of non-steel linings was improved with the increase of graphite flakes on the disk surface and steel -containing linings
showed good fade resistance regardless of graphite contents in the gray iron disks.
2016 Elsevier Science Ltd. All rights reserved.
Keywords: Gray cast iron; Friction characteristics; Graphite; Ferrite; Carbon equivalent; Brake linings
0301-679X/03/$ - see front matter 2003 Elsevier Science Ltd. All rights reserved.
doi:10.1016/S0301-679X(02)00260-8
538 M.H. Cho et al. / Tribology International 36 (2016) 537–545
Table 1
The composition of the step block castings in weight %
Cast No. C Si Mn P S Cu Ni Cr V Mo Ti Fe CE
1 3.32 1.7 0.52 0.03 0.1 0.15 0.03 0.04 <0.01 0.01 0.01 bal. 3.89
2 3.46 1.8 0.52 0.03 0.1 0.15 0.03 0.04 <0.01 0.01 0.01 bal. 4.06
3 3.68 2.0 0.52 0.03 0.1 0.15 0.03 0.04 <0.01 0.01 0.01 bal. 4.35
Table 2
Ingredients in the brake linings produced for this study (amounts in
volume %)
Panel (i)
Phenolic resin 15
Aramid pulp 10
Rockwool 5
Cashew particle 10
Graphite 10
ZrSiO4 5
BaSO4 20
Ca(OH) 2 4
Steel fiber 0 15
Ceramic fiber 4 0
Potassium titanate 17 0
Iron powder 0 6
Panel (ii)
Table 3
Tribotest procedures employed in this study
a.
The number in the square brackets represents the unit area pressure experienced by the friction material.
b.
The high temperature drag is a constant interval test consisting of 60 sec drag with 15 sec interval and repeated 15 times.
M.H. Cho et al. / Tribology International 36 (2016) 537–545 541
Fig. 5. (a) (Top) Ternary diagram showing relative amounts of phases on the gray iron disk surfac es. (b) (Bottom) Microstructures observed on
the surface of disk specimens that correspond to a, e, and i in the ternary diagram; graphite morphology is shown before etch ing and matrix
morphology and distribution of free ferrite are seen in the post etched micrographs.
3.2. Friction characteristics as a function of rotor surface. This was an interesting result since higher COF
microstructure values were expected as the amount of ferrite increased
in the case of steel-containing linings due to material
3.2.1. Effect of free ferrite on friction coefficient compatibility between steel fibers in the lining and the
Free ferrite forms in gray iron when carbon and silicon free ferrite in the gray iron disk [21]. This result suggests
contents exceed the amounts that are needed to form that the two metallic phases (ferrite and pearlite) have a
pearlite during cooling [20]. The ferrite in the gray iron similar level of friction effectiveness when they are
disk samples in Fig. 6 is produced from the decompo- rubbed against two brake linings, or that at these low
sition of cementite at elevated temperatures, and it often percents of ferrite its presence does not alter the friction.
appears near graphite flakes since carbon in the cement- Fig. 7 also indicates that the lining B has a slightly
ite precipitates as graphite during decomposition. The higher coefficient of friction than the lining A suggesting
effect of ferrite in gray iron on the COF was examined that the lining B can produce more frictional heat than
by testing gray iron disks containing different amounts lining B during sliding if the friction test is carried out
of ferrite on their surfaces. Six gray iron disks with simi- for the same amount of time. However, the measured
lar area % of graphite were chosen for this analysis as temperature rise at the sliding interface during this short
shown in Fig. 7 (group X). Fig. 8 shows the effect of drag tests was less than ten degrees, which appeared to
ferrite phase on the COF. Results showed that the COF have little effect on the COF in this experiment.
was not affected by the amount of ferrite on the disk
542 M.H. Cho et al. / Tribology International 36 (2016) 537–545
Fig. 6. Graphite area % as a function of average length of graphite Fig. 8. Effect of free ferrite on the coefficient of friction.
flake.
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