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Copper is one of the most important components in brake pads and its amount can reach up to 14%. In spite of a number of positive features copper usage in brake pad formulations has recently become the subject of considerable discussions, primarily due to concerns about potential risks related to environmental impacts of copper particles. So, for developing new pad formulations with possible replacements of copper content, it is very important to understand the functionality of copper additions to brake friction materials. In the paper theoretical investigation of the role of copper as a pad ingredient was carried out on the basis of modelling by the method of movable cellular automata (MCA). Our previous studies show that copper as a constituent of the tribofilm formed during braking provides smooth sliding by forming a granular layer of mechanically mixed materials from the friction layers. In the present study the concentration of copper particles in a Fe3O4-matrix was varied systematically in the range 5.5-28 vol. % and compared to mixtures with the same amount of graphite nanoparticles. The sliding simulations were performed while assuming material properties at 500°C in order to assess the beneficial role of copper during severe braking conditions corresponding to fading cycles during dynamometer testing.
In order to obtain a better understanding of the role of tribofilms during automotive braking, their structures were investigated and the essential features identified.
Next, different ingredient combinations were studied by preparing some model materials with simpler compositions than real tribofilms. A test method was developed for verifying the tribological properties of the model materials and for comparison with results obtained with numerical sliding simulations of such structures. Prerequisites of good brake Performance properties were identified. Although the coefficient of friction could be varied in a wide ränge, smooth sliding conditions could only be achieved with values smaller than 0.4. Tests with artificial third body powders turned out to be useful as screening method for the selection of raw materials for brake pad formulations.
In part 1 it was shown that tribofilms usually are 100 nm thick and exhibit a multiphase nanocrystalline structure. The objective of our modelling efforts was to obtain a better understanding of the sliding behaviour and associated friction properties and to study the impact of internal and external parameters on these properties. The method of movable cellular automata (MCA) was used. The third bodies were considered as aggregates of linked nanoparticles which may decompose and form a layer of granulär material, the so-called mechanically mixed layer (MML), if certain fracture criteria are fulfilled. The basic model structure which consists of Fe3Ü4 nanoparticles with 13 % graphite inclusions was used. In order to assess the robustness of the model the following parameter studies were performed. The pressure ränge at an asperity contact was varied between 15 and 50 MPa. The mechanical properties of the oxide were varied between brittle and ductile behaviour corresponding to room temperature and high temperature behaviour. The mechanical properties of the soft ingredient were varied + 50 % of the properties of graphite. The influence
Automotive brake pads consist of many components but it is still not entirely clear which role each of the elements of this complex composition plays to provide the specified regimes of sliding. This is due to the mutual interaction of multiscale mechanisms, realized during the friction.
In this work we have attempted to partly answer this question using computer simulations. Since the simulation allows us to consider various combinations of the structure of the system being simulated ceteris paribus, it becomes possible to understand the role of each constituent sequentially. The main attention is paid to the structure and composition of the thin film that forms on the surface of both bodies as a result of compaction of the wear product, its chemical composition and oxidation. This layer, also named a third body or friction film, differs in composition and microstructure from the two first bodies. We considered a single contact for the steady state sliding when the structure and composition of friction films already are formed. As a modelling tool we used the method of movable cellular automata, which has well proven itself in solving of such tasks. We investigated the influence of modification of the structure and composition of the third body on the features of system behaviour at friction. To assess the adequacy of the numerical model, experimental studies with an artificial third body were also carried out. The Simulation results are in good agreement with experimental data.