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In this study, a functionally gradient iron-based brake pad material was developed and the tribological behavior was studied. The functionally gradient specimen had more copper near the base plate and more abrasives towards the top, which provides excellent joint strength and serves the purpose of braking, respectively. The layers had a hybrid composition of metallic materials (Fe, Cu), and abrasives (silicon carbide and aluminum oxide) to improve the strength, wear resistance, and toughness. Graphite was added to stabilize the specimen's thermal and friction characteristics at high temperature. The microstructure, wear rate, and friction coefficient of the functionally gradient specimen and the conventionally sintered specimen were evaluated. The results indicate that the wear resistance of the functionally gradient specimen is higher than the wear resistance of conventional specimen.

This article investigates the role of friction stir processing (FSP) process parameters on the evolution of microstructure, hardness, intergranular corrosion resistance and wear resistance of aluminium alloy AA5083. The FSP trials are performed by changing the process parameters as per face-centered central composite design. The friction stir processed (FSPed) specimens subjected to intergranular corrosion test and wear test are characterized using field emission scanning electron microscope, energy dispersive x-ray spectroscopy and X-ray diffraction. Outcomes suggest that grain refinement, dispersion and partial dissolution of secondary phase has simultaneously increased the hardness, intergranular corrosion resistance and wear resistance of the FSPed specimens. The study found that tool rotation speed of 700 rpm, tool traverse speed of 60 mm min −1 and shoulder diameter of 15 mm results in maximum hardness, wear resistance and intergranular corrosion resistance.

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