Development of Iron Based Brake Friction Material by Hot Powder Preform Forging Technique used for Medium to Heavy Duty Applications

Mohammad Asif, K. Chandra, P.S. Misra

Metallurgical and Materials Engineering Department, Indian Institute of Technology,Roorkee. Roorkee- 247667, India.

DOI: 10.4236/jmmce.2011.103015                

Abstract

A promising friction material, Iron -based friction material, was prepared by powder metallurgy (PM) processing utilizing hot powder preform forging (near net-shape).The preparation of the product and its characterization are presented in this paper. These products are useful in heavy duty Military Aircraft applications such as AN-32. In order to eliminate costly environmental control systems to protect products during their high temperature processing (as is conventionally practiced employing hydrogen gas), the present investigation relies on carbon (mixed in the brake pad formulation) as reducing agent and high temperature oxidation resistant glassy coating (separately developed) applied over the product’s surface after cold compacting. After conducting an initial characterization such as hardness, density and Pin-on Disc tests, the samples were tested in sub-scale dynamometer under Rejected Take Off conditions. It was observed that the obtained density in the present investigation is higher than the reported density obtained by sintering route, and wear is on the lower side of the range as per the Aeronautical Standards. Optical metallography was used to investigate the microstructure of friction, interface and backing layer. It was observed that the distribution of ingredients in matrix was homogeneous. The results also indicate that the coefficient of friction is more stable, and wear is lower with respect to temperature rise. .

Keywords

Forging, Powder Metallurgy, Friction material, brake pad

Conflicts of Interest

The authors declare no conflicts of interest.

References

[1]	Czichos H., Molgaard J., “Towards a general theory of tribological systems”, Wear,14, 1977, pp. 247-264.
[2]	Lazarev G.E., 1971, “Evaluation of wear resistance of friction materials”, Powder Metallurgy and Metal Ceramics, 7, No. 10, pp 903-905.
[3]	Garbar II., 1997, Wear, “The effect of load on the structure and wear of friction pair materials”., vol 5, pp205:240.
[4]	Tu JP, et al. Friction and wear behavior of Cu–Fe3Al powder metallurgical composites in dry sliding., 1998 ,Wear; vol 9, pp220-272.
[5]	Tyler.G.Hicks, ‘Handbook of mechanical engineering calculations-II edition’, ISBN 0071458867, 2006, McGraw-hill publications.
[6]	Dixon R.H.T., Clayton A., ‘Powder Metallurgy for engineers’, Machinery Publishing Co. Ltd. London., 1971, pp166-183.
[7]	Shvedkov E.L., Derkacheva G.M., Panaioti I., ‘Optimization of the manufacture of a sintered iron-phosphorus base frictional material’, Powder metallurgy and metal ceramics vol. 14, No. 4, 1975, pp304-307.
[8]	Prochazka V., Navara E., Miskovic V., Kosta K., ‘The influence of copper on the properties of sintered iron-graphite friction materials’, published in ‘Perspective in Powder Metallurgy: Friction and Antifriction Materials –Vol. 4’, edited by Hausner Henery H., Roll Kempton H., Johnson Peter K. Plenum Press, New York, London. 1970, pp123-127.
[9]	Dutta D., Mohan G., Chatterjee B., Krishnadas Nair C.G., ‘Development of sintered metalloceramic friction material for the wheel brakes of a military transport aircraft’, Published in, ‘Composites: Science and Technology (ISBN 81-224-1251-3)’ edited by R.C. Prasad, P. Ramakrishan, New Age International (P) Ltd., New Delhi., 2002, pp 94- 114.
[10]	Kryachek, V. M., Jan., 2005, ‘Friction composites: Traditions & new solutions (review). parts2. Composites’, Powder Metallurgy & Metal Ceramics, Vol. 44, pp05-16.
[11]	Misra P. S., Chandra K. “Development of High Temperature Oxidations Resistant Glassy Coating” Indian Patent, application No. 153/DEL/2010 dated Jan. 27, 2010.
[12]	Chaturvedi A. K., Chandra K., Misra P. S. October 2009, Journal of Tribology, “Wear Characterization of Al/Ingredients MMFC” vol. 131 / 041601-1.
[13]	Asif M., Chandra K., Misra P. S., 2010, “Tribological studies of iron-based brake pads made by P/M route used for heavy duty applications” submitted and presented in International conference organised by PMAI, Jaipur, India (held Jan.28-30, 2010). published in transaction of PMAI, Vol. 36, 2010, pp78-81.