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A bottom-up approach to study metal sulphides in brake friction materials at higher temperatures
(2017)
The impact of metal sulphides in brake friction materials on the friction behaviour of disc brakes was studied at two different temperatures and in two different atmospheres using a pin-on-disc device with powder supply. Powder mixtures were prepared by using a bottom-up approach, where magnetite is the main component, in which different metal sulphides are mixed in. At 400 °C, the resulting coefficients of friction are higher in air than in nitrogen atmosphere, which can be attributed to the generation of metal oxides and were confirmed by doing thermal analysis.
A bottom-up approach to study metal sulphides in brake friction materials at higher temperatures
(2017)
The impact of metal sulphides in brake friction materials on the friction behaviour of disc brakes was studied at two different temperatures and in two different atmospheres using a pin-on-disc device with powder supply. Powder mixtures were prepared by using a bottom-up approach, where magnetite is the main component, in which different metal sulphides are mixed in. At 400 °C, the resulting coefficients of friction are higher in air than in nitrogen atmosphere, which can be attributed to the generation of metal oxides and were confirmed by doing thermal analysis.
Metallsulfide werden den meisten Bremsbelägen als Reibungsstabilisatoren zugesetzt, obwohl die Auswirkungen auf die Bremsleistung sowie die Art und Weise, wie sie im dritten Körper wirken, wenig verstanden ist. Um zu untersuchen wie synergistische Effekte im Tribofilm das Reibverhalten bestimmen, wurde eine Stift-Scheibe-Anordnung mit Pulverzufuhr genutzt, welche einen künstlichen dritten Körper erzeugt. Die verwendeten Pulvermischungen wurden nach dem Bottom-up-Prinzip entwickelt: Beginnend mit Einstoffsystemen wird über Zweistoffsysteme aus Magnetit und Metallsulfid (Massenanteile: 85 % zu 15 %) zu Dreistoffsystemen aus Magnetit (85 %), Graphit (7,5 %) und Metallsulfid (7,5 %) entwickelt. Zusätzlich wurden ausgewählte ternäre Pulvermischungen mittels Hochenergie-Kugelmühle gemahlen, um Partikelgrößen im Nanometerbereich zu erhalten. Sämtliche Pulvermischungen wurden bei Raumtemperatur und bei 400 °C getestet, um die höheren Beanspruchungen während eines Bremsvorgangs zu simulieren. Des Weiteren wurde in oxidierender und nicht-oxidierender Atmosphäre getestet, um den Einfluss der Oxidbildung zu identifizieren. Die mittleren Reibungszahlen bei 400 °C und in Luft sind durchschnittlich höher als in Stickstoffatmosphäre, was der Bildung von Metalloxiden zugeordnet werden kann und durch thermische Analysen an den Pulvern bestätigt wird. Es zeigt sich, dass die Verwendung von nur einem Metallsulfid in einer Rezeptur für Bremsbeläge nicht ausreichend ist, um die Reibungszahl dieses Tribosystems unter verschiedenen Beanspruchungen zu stabilisieren. Ein stabileres Reibverhalten konnte erreicht werden, indem zwei verschiedene Festschmierstoffe als Reibungsstabilisatoren kombiniert wurden.
A study on metal sulphides in tribofilms of modelled brake wear debris under variable humidity
(2017)
Metal sulphides are needed in brake pad formulations in addition to graphite to compensate the influence of different environments. The sensitivity to humidity differs a lot for each single constituent. Only one component is not sufficient for stabilising the COF and it is also necessary to add more components than only one metal sulphide to graphite. Furthermore, a good mixing process inside the third body during braking is necessary to prevent formation of solid lubricant films which are detrimental for braking. Nevertheless, not every metal sulphide acts as a solid lubricant but most of them have the ability for stabilizing the friction coefficient.
To investigate the influence of metal sulphides in brake pads, powder mixtures with up to three components were tribologically stressed in a pin-on-disc device under different levels of relative humidity. The tests revealed that each metal sulphide causes significant differences in resulting coefficients of friction as well in their sensitivity to humidity, so that only one solid lubricant cannot stabilise the friction behaviour during braking in different environments.
Besides carbon, metal sulphides are used in every standard brake pad formulation as friction stabilisers. In order to investigate their impact, various powder mixtures were tribologically stressed in a pin-on-disc device in order to produce and test artificial third bodies. containing the three main components of a real friction film, namely magnetite, graphite and a metal sulphide of interest. Since the sliding behaviour is influenced by the relative humidity the powder mixtures are tested at low, medium and high moisture levels. The tests revealed that the presence of graphite dominates the friction behaviour as well as the humidity sensitivity.
The powders were prepared by either manual mixing or high energy ball-milling. Interestingly, all ball-milled blends provided coefficients of friction within the desired range for braking, which was attributed to the effect of zirconia particles from wear debris of the milling balls. The zirconia particles prevent the formation of solid lubricant films on the surfaces and support a homogeneous mixture of all constituents of the powder. Optimum brake performance is gained by an optimum combination of solid lubricants and abrasives.