Abstract
•Interdependencies between the performance influencing parameters are established.•The constituents role is influenced by the heterogeneity of the friction material.•The anisotropy of the material depends essentially on the fiber orientation.•The ability of fibers to participate on load-bearing depends on their orientations.
The interaction between microstructure, mechanical, and frictional properties of a commercial brake lining material (BLM) was investigated in order to correlate them to braking performance. For this purpose, a Scanning Electron Microscope (SEM) with energy dispersive X-ray (EDX) mapping and spectrum were used to identify and analyze different constituents. The mechanical properties were determined using compression test. Relevant physical properties (density and porosity) were determined using standard test methods. The friction coefficient and wear behavior of the friction material on contact with the grey cast iron disc were established using a pad-on disc tribometer. The results have shown that the brake lining material contains phenol resin such as the matrix and other various ingredients, including silica, rock and mineral filler reinforcement, barium sulfate and carbon-rich particles as filler and brass particles as friction modifier. It had a varied amount and size up to 1mm for brass particles. The density and porosity were 1.8gcm−3 and 7%, respectively. The investigated material exhibited excellent mechanical properties in the normal solicitation direction. The average friction coefficient was about 0.65, whereas the friction coefficient was stable. The different actions of various ingredients in terms of their effects on the friction and wear behavior of the BLM could be related to their different bonding strengths with the resin matrix and their different abilities to form friction films (third-body layer) on the surfaces of the material and transfer films on the counterpart cast iron surface in relation to the surface temperature evolution and mechanical properties.