The purpose of friction material is to decelerate a vehicle by transforming the kinetic energy of the vehicle into heat, via friction, and dissipating that heat to the surroundings. A lot of heat is generated at the contact plateaus formed by the reinforcing fibers. Therefore, inorder to dissipate the heat, steel fibers were coated with FeS and SnS and accordingly brake pads were made and termed as DBF and DBS. Another brake pad with similar formulation but with a mixture of steel fiber, FeS and SnS was made (designated as DBO) for comparison. All three brake pads were tested in an inertia brake dynamometer with a typical schedule. The speed spread (100/50 Kmph) 0.6g and effectiveness variation of all the pads are fallen in the required range. The fade I of DBO is observed 32.8% lesser whereas for DBS and DBF, it is observed10% and 15.7% more than the standard values, respectively. DBF and DBO have shown 25.4% and 39.6% more wear than DBS, respectively. Further, it is observed a more consistent µ during single braking to identify fade during stops in the second effectiveness test. It is evidenced for the increase in the life of the friction film formed by the sulfide coated fibers in DBS which has increased its wear resistance (Max Δµ = 0.10 for DBS, 0.29 for DBF, and 0.30 for DBO). It is also noticed that the radial wear of all three brake pads was greater than the tangential wear and their ratios are 1.36, 1.40 and 1.55, respectively for DBS, DBF and DBO. Moreover, the optimization has revealed the DBS as best performer friction materials formulation.
Metal sulfides play a major role in determining the friction and wear performance of the brake friction composites. The usage of the combinations of metal sulfides improves tribological performance compared to its individual metal sulfides in the formulation of friction material. In this work, the effect of the Bismuth III sulfide and Iron disulfide combination was evaluated against the tribological performance in the formulation of the friction materials. Six brake friction pads were developed by properly balancing the weight percentage of Bismuth III sulfide and Iron disulfide in the formulation. The tribological performance of the friction liners was studied using a chase tribo-meter following the IS2742 test protocol. The worn surfaces of the brake pad samples were examined for its surface morphology and elemental behaviour using a Scanning electron microscope and an Energy-dispersive X-ray spectroscope. It was observed that the partial replacement of the Bismuth III sulfide with Iron sulfide improves the friction and fade performance. The abrasive nature of the Iron sulfide in the friction pad increases the coefficient of friction and causes the high wear loss beyond the ratio of 4:6 of the mixed sulfides. A statistical approach named preference selection Index was employed to rank the brake friction materials based on the multiple performance criteria.
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