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Journal of Engineering Research and Studies

Review Article

ALTERNATE MATERIALS IN AUTOMOBILE BRAKE


DISC APPLICATIONS WITH EMPHASIS ON AL
COMPOSITES- A TECHNICAL REVIEW
Telang A K*1,Rehman A2,Dixit G3,Das S4

Address for Correspondence


*1 Asstt. Professor, Maulana Azad National Institute of Technology, Bhopal, M.P. ,India
2

Associate Professor, Maulana Azad National Institute of Technology, Bhopal, M.P. ,India
3

Professor, Maulana Azad National Institute of Technology, Bhopal, M.P. ,India


4

Advanced Materials Processes Research Institute, Bhopal, M.P., India


Email- * atelang7@rediffmail.com

ABSTRACT
Brake technology just like suspension & fuel system technology has come a long way in recent years.
Automobile braking systems normally use brake discs of steel or grey cast iron, which are then paired
with composite organic brake pads. These types of materials are suitable for use in braking systems with
moderate loads, but vehicle manufacturers are tending to design increasing number of vehicles with more
braking power. In addition, a history of high operating costs for on - highway vehicles and for aircrafts
has encouraged designs for weight reduction with long service of braking systems. Redesigning of the
braking system by substitution of lighter material like aluminum and carbon composite brakes primarily
have been responsible for this state of the art technology, which is being used in aircrafts and formula
one racing cars (1).The requirement is of the materials that have light weight, are strong, abrasion
resistant and are not corroded easily. Composite materials provide such unique combination of
properties. In this review the alternate materials for automobile brake applications with special attention
to aluminum composites has been done.
KEYWORDS Braking systems, organic brake pads, composite materials, aluminum composites.

INTRODUCTION
The need of efficient use of energy &
materials is being felt strongly because of
diminishing resources in the present times.
There has been an important role of
materials

in

the

development

of

civilizations. In the transportation sector


when earlier large bulky automobiles are
compared

with

todays

light

weight,

technologically superior vehicles. Man has


JERS/Vol. I/Issue I/July-Sept. 2010/35-46

been using iron, copper & their alloys for


thousands of years, but surprisingly until the
last century he was oblivious of the bauxite
ore(which has aluminum) is the second most
abundant ore in earth crust. It became an
economic competitor to steel & cast iron in
engineering applications because of its
excellent combination of properties like
lightweight, high specific strength, stiffness
& good corrosion resistance, higher ductility

Journal of Engineering Research and Studies

etc. However, the poor mechanical and

appearance when anodized. In internal

tribological properties of aluminum (yield

combustion engines, Al-Si alloys are used

strength : 30 Mpa, tensile strength : 70 Mpa)

extensively because of their properties like

(2) limits its wider range of usage. Realizing

low

the potential as well as availability of

bearing properties, good corrosion resistance

Aluminum, considerable efforts are being

in association with the strength.

made

Composite Materials

to

explore

the

possibilities

of

coefficient

of

thermal

expansion,

improving the mechanical strength and wear

Composite materials signify that two or

resistance so as to meet the requirements of

more

various applications. More aluminum is

microscopic scales to synthesize a useful

being consumed now a days than all other


non ferrous metals/ alloys including Copper.
The transformation of the automobiles
requiring more fuel, frequent maintenance to
the energy efficient automobiles requiring
lesser maintenance and which are also
environment friendly has resulted from
better engineering & materials. With the

constituents

are

combined

on

material. A variety of materials can be


combined on a microscopic scale. The
advantage of the composite materials is
that their individual constituents retain
their characteristic unlike alloys. As a
result, various combinations of useful
properties, usually not attainable by

turn of century material technology in

alloys,

automobiles undertook a shift towards all

composite materials by suitable tailoring

aluminum cars. In order to improve

the

mechanical

strength

&

modulus

the
of

can

be

matrix

[dispersoid].

obtained

and
The

through

reinforcement
dispersoids/second

aluminum, it is alloyed with various alloying

phase particles may be either harder or

elements such as Cu, Zn, Mg, Si, Mn etc.(3)

softer than the matrix alloy and affect the

Amongst the various Aluminum alloys Al-

properties of the composites accordingly.

Zn-Mg alloys are found to show tremendous

For e.g. softer dispersoids like graphite,

improvement in mechanical strength and


finds its application in aerospace and
automobile structural components. Al-Mg
cast

alloys

show

excellent

corrosion

resistance, good machinability and attractive

talc,

shell

etc.

impart

solid

lubricating properties wherein the total


wear resistance of the material improves
(4-5). In this case, other properties such
as

JERS/Vol. I/Issue I/July-Sept. 2010/35-46

mica

strength,

hardness

etc.

of

the

Journal of Engineering Research and Studies

composites is less than that of the matrix

phase has an aspect ratio [i.e. ratio of length

alloy. However, they have been found to

to diameter] from 50 to 10,000. A number of

be within acceptable limits as confirmed

such composites with reinforcement of

through some experiments (6-8). The

alumina

reinforcement of hard ceramic particles


like silicon carbide, alumina, silica,
zircon etc. in aluminium alloys has been
found to improve the wear resistance as
well

as

high

temperature

strength

properties (9-11).

fibres,

boron,

silicon

carbide (12,13) are now commercially


available

for

requiring

exceptionally

structural

applications
high

specific

strength and specific modules. The second


category

of

composites

involves

the

dispersion of soft or hard particles. These


composites

Types of Composite Materials

carbon,

are

of

great

interest

in

tribological applications. In the case of

The nature of the reinforcing phases and the


matrix are the important factors on the basis
of which composites are classified as:

particle dispersed composites there can be


some

reduction

in

tensile

strength

[especially at room temperature], ductility

a) Fibre reinforced composite

and fracture toughness (14). These can be

b) Whisker reinforced composite

used by tribological purpose where strength

c) Particle reinforced composite

is not the-main criterion (15). In the case of

d) Laminated composite

laminated composites, alternate layers of

Different types of composites with reference


to the nature of the matrix are as follows:

different materials are put over each other


with the help of some binding agents. In

Ceramic Matrix composites [CMCs]

some cases secondary processing is also

Metal Matrix composites [MMCs]

required in order to improve the strength

Polymer Matrix composites [PMCs]

properties of the composites.

Fibre reinforcements dominate composites.

Aluminum Matrix Composites (AMCs)

The reinforcing phase may be continuous,

There is a broad family of materials in this

that is, extending the full length of the

category aimed at achieving an enhanced

composite

or

combination of properties and this can be

discontinuous [as particulates, whiskers or

attained by selecting different matrices as

short fibres]. In the fibre reinforced and

well as reinforcing phases. In addition to the

whisker-reinforced composites, the second

matrix microstructure, reinforcing phase

[as

wire

or

filament]

JERS/Vol. I/Issue I/July-Sept. 2010/35-46

Journal of Engineering Research and Studies

also controls the characteristics attainable by

2. Continuously reinforcement aluminum

the MMCs (16). Matrices reinforced with

alloy composites [long continuous fibre

high modules short fibres, whiskers or

reinforced].

particulates have improved strength and


stiffness and are isotropic in nature. This
variety of the composites is less expensive
to produce. In the case of continuous fibre or
whiskers with high aspect ratio [length /
diameter], to align fibres in the desired stress
direction and to transfer the applied load to
the fibres the matrix serves to hold them
together. The mechanical properties of the
composites

are

dependent

upon

the

efficiency of the matrix in transferring the


load to the reinforcement fibres and are
therefore related to the quality of the
fibre/matrix interfacial bonding (17). This
type of composites exhibits significantly
higher strength and stiffness. But they are
non-isotropic in nature and are expensive.
Aluminium and its alloys form the most
widely investigated matrix for use in
MMCs. This popularity of Al-alloy as a
matrix material can be attributed to its low
cost relative to other light structural metals
such as Mg, Ti, etc. its current dominance
on the aerospace structural application and
so on. There are two types of reinforced
aluminum alloy composite:

The early work on composites, considered


that the continuous fibre reinforcement
composites are very expensive and hence
limit their applications (18). It was apparent
that the cost of continuous fibres, complex
fabrication routes, and limited fabricability
would restrict their use to those applications
requiring the ultimate in performance. This
led to the development of discontinuously
reinforced composites, particularly short
staple Al2O3 fibre and SiC whiskers (5)
reinforced composites. Discontinuous fibre
has

found

and particulate reinforced] and


JERS/Vol. I/Issue I/July-Sept. 2010/35-46

application

as

selective reinforcement in the ring land area


of

diesel

piston

[24]

and

whisker

reinforcement is under development for


aerospace applications. Particle reinforced
light metals, with their potential as low cost,
high modulus and strength, high wear
resistance and easily fabricated material, are
just reaching the commercial production
stage.

Understanding

the

factors

that

influence the physical and mechanical


properties of these materials is yet to be
crystallized, because they are sensitive to
several

1. Discontinuously [short fibre, whisker

commercial

factors

like

the

type

of

reinforcement, the mode of manufacture and

Journal of Engineering Research and Studies

the details of any fabrication processing of

system. Saka and Karaleskar (23) reported a

the composite after initial manufacture etc.

decrease in sliding wear resistance, with

Wear of Al matrix composites


The property of wear behavior in the
application of brakes is most vital. A
number of investigators have studied the
friction and sliding wear behaviour of AI-Si
alloy composites It is well known that
improvement in the wear resistance of
Aluminum alloys can be achieved by adding
(19) ceramic particles such as SiC and Al2O3
to the matrix alloy (20). Particle-reinforced
metal matrix composites [MMCs] have been
used in brake and piston components in
automobile and aircraft's over the last
decade owing to their attractive friction and
wear properties (22). It has been found that
the wear resistance of Aluminum matrix
composites is influenced by numerous
factors such as the morphology, size and
volume fraction of reinforced particles as
well as the strength of the interface. Hosking
et al (21) observed an increase in wear
resistance of 2014 Al-Al2O3 with increasing
weight percent and size of ceramic particles.
However conflicting reports exist in the
literature when metallic interfaces are used
as rubbing pairs. For example, Alpas and
Embury observed a decrease in the sliding
wear resistance with increasing particle
volume fraction in a 2014 Al-SiC/steel
JERS/Vol. I/Issue I/July-Sept. 2010/35-46

increasing particle concentration in a CuAl2O3 composite,

Therefore, the selection

of the rubbing pairs with metal matrix


composites seems important and different
wear mechanisms may result in different
wear behaviour. Because steel or steel alloy
components as wear counter faces are
widely used in tribo systems, the study of
MMCs/steel wear system has become an
important topic in recent years. Lhasa et al
(25) have studied the wear resistance of
various eutectic and hyper eutectic Al-Si
alloys

with

various

compositions

and

processing routes on pin on disc machine at


two different test speeds.At lower disc speed
the influence of the composition and alloy
processing is very strong and a severe wear
transition is observed for the alloys with low
fraction of primary Si particle. At higher
disc speed wear of all alloys except the one
with high silicon content, is very low. The
higher wear is caused by cracking & fracture
of large Si particles upon impact with
abrasive disc material. Jang H and others
(26) have reported the effect of different
metallic fibres (Cu, steel and Al ) upon
friction and wear performance of various
brake disc (grey cast iron and aluminum
MMC)

to

investigate

the

friction

Journal of Engineering Research and Studies

characteristics such as speed sensitivity,

behaviour of composites and set design

pressure

fade

guidelines for manufacturing of materials

resistance and wear resistance. When the

with optimum tribological properties. The

grey cast iron is used as a counter disc at

wear behaviour of these alloys has been

low temperatures, the friction material

studied in details [32-37] and it has been

containing Cu or steel showed high speed

shown that eutectic and hypereutectic

sensitivity, when Al-MMC disc are used the

composites

speed

resistance.

sensitivity,

sensitivity

different

friction

temperature

was

small

materials.

between
High

temperature fade resistance was improved


by using friction materials with copper or
steel fibres on the grey cast iron. The
greatest amount of wear occurred in the
friction material containing steel fibres
followed by copper fibre friction and Al
fibre friction materials. Recent studies [27]
revealed that in addition to the volume
fraction, and spatial distribution of second
phase particles, wear resistance is largely
affected by the strength of particle-matrix
interfaces as well as the mechanical
properties of matrix materials, consequently
under the service conditions where the
particles lose their ability to support the
applied load [either owing to interfacial,
depending, particle fracture or pull out]
second phase reinforcement may cause no
improvement or even a deterioration in the
wear

properties

[28-31].

detailed

understanding of the micro mechanism of


wear is necessary to model the wear

exhibit

the

highest

wear

Review of brakes
Automotive brakes include drum and disk
brakes for vehicle applications. Drum brakes
predominantly use internally expanding
shoes with brake linings that load the
majority [typically 50 to 70%] of the drum
rubbing surface. Most automotive disk
brakes use shoes that load a much smaller
portion [from 7 to 25%] of the disk rubbing
surface. Disk brakes offer faster cooling,
with their larger exposed surface areas and
better cooling geometry, but are more
vulnerable

to

either

liquid

or

solid

particulate contamination. Rhee and others


have related measurements on friction
material wear with the brake cast iron
temperature.
essential

These

constant

data
wear

indicated
rate

for

an
low

temperature and a nearly exponential one at


elevated temperature (38). Because of
cooling, contamination, and other basic
design issues, front disk brakes and rear
drum brakes are commonly used. The

JERS/Vol. I/Issue I/July-Sept. 2010/35-46

Journal of Engineering Research and Studies

friction material is called a brake lining,

discs in railway braking devices differing in

whether it is used on drum .Drum brake

matrix composition in continuous braking

linings are known as segments or strips, and

against an organic pad. They have reported

heavy truck drum brake linings are called

that AMC discs show lower friction

blocks. Particulate reinforced aluminum

coefficients and higher wear rates than

MMC s are promising candidate for

classical steel discs. By increasing the

automotive applications since they offer

reinforcement rate upto 8 weight percentage

high specific stiffness and strength, good

angular SiC, the disc exhibited a low wear

wear

thermal

rate, particularly at high braking power and

properties; further more, they are readily

a relatively high friction coefficient because

available at reasonable prices and can be

of high angular SiC content with same SiC

processed using conventional technologies.

content,the spherical SiC reinforced disc

(39) A review of disc materials used by the

exhibited a lower friction coefficient due to

automotive industry today, will show that

spherical SiC reinforced disc exhibited a

there are two basic material philosophies.

lower friction coefficient due to spherical

The first, used for family sized vehicles,

morphology resulting in a sliding contact

operates on the principal of small diameter,

instead of ploughing one. M J Denholm,

high strength, discs with sufficient inherent

[42] has reported the use of Al MMC rotor

strength to resist any tendency towards the

and drum technology and how it might

formation

and

move light vehicle brake systems to new

distortion at high operating temperatures.

levels of customers satisfaction. AL MMC

These discs whilst having good strength

technology exhibits a remarkable fit, in

properties have relatively low thermal

addressing all of these areas simultaneously

conductivity. The second principle, that of

while

large weaker, low strength discs with high

reduction. Nobuyuki and others (43) have

thermal conductivity, has been applied more

developed the laboratory tests for studying

commonly, to the larger high powered type

local physical phenomenon caused by

of vehicle where space constraints are not so

friction in railway braking. Similar contact

critical, and as a consequence, a large

conditions to those at full scale have been

diameter thicker discs can be employed.(40).

generated. An original braking tribometer is

Laden and others (41) have tested four AMC

presented

resistance

of

and

thermal

suitable

cracking,

JERS/Vol. I/Issue I/July-Sept. 2010/35-46

offering valuable

whose

design

rotating mass

is

based

on

Journal of Engineering Research and Studies

similitude rules between reduced scale and

reinforced with different sizes of SiC

full scale. The drive to reduce vehicle

particles. It is found that the brake material

weight, and improve efficiency, has led to

against the drum with large size SiC

the investigation of alternative materials for

particles

use as brake disc materials. To date, two

performances and wear resistance than those

alternative

carbon

against the former associated with small

composites and aluminium metal matrix

sized SiC particles. Friction coefficient in

composites have found limited use. Blau et

both decreased with increase of load and

al (44) have done the sliding friction and

speed. Friction fade took place at high

wear tests simulating the geometry of a flat

temperature. Natrajan et al (46) have

brake pad on a flat rotor, on four different

compared the wear behavior of aluminum

material combinations; commercial pad

metal matrix composite sliding against

material

ceramic

automobile friction material and reported the

composite (C/SiC) sliding self mated,

friction coefficient of Al MMC 25% higher

commercial pad material on Al metal matrix

than cast iron. The influence of load and

composite and commercial pad material on

temperature on the dry sliding wear of Al

iron alumina alloy. They have reported that

based composites against friction material

average friction coefficients were similar for

has been investigated by Straffelini et al

the sliding couples involving cast iron and

(47), they have found that wear resistance of

the ceramic composite but were lower for

Al MMC brake rotors are superior to those

the other two, with lowest being for the

of cast iron rotor if the structure and

couple containing the MMC. The surface

composition of lining material are correctly

roughness of the cast iron and ceramic

modified. Das and others (48) have noted

composite disc were reduced after sliding,

that wear rate of composite (Al Si alloy with

but that of the MMC remained about the

SiC reinforcement) is less than that of Al Si

same, and that of intermetallic alloy

alloy, hardness and strength of composite

increased due to abrasive wear. Zhang and

are higher than that of alloy and they

Wang (45) have investigated the friction and

increase with increase in SiC content. The

wear behavior of the same brake materials

wear rate of Al alloy and Al composite is

dry sliding against two different brake

invariant to the sliding distance and increase

drums made of Al Matrix composite

with increase in applied load and abrasive

materials,

on

grey

cast

carbon

iron,

JERS/Vol. I/Issue I/July-Sept. 2010/35-46

showed

better

friction

Journal of Engineering Research and Studies

size. Addition of SiC particles and heat

reported

treatment provide comparable improvement

coefficient vary with applied load and

in wear resistance. Kaynak and Boulu (49)

sliding speed and a tribolayer can act as a

have investigated the friction behavior of Al

protective layer for the matrix material. In

matrix-SiC particulate reinforced composite

the study of wear & friction behavior of SiC

specimens in comparison to the matrix Al

particle

alloy containing 12 weight percentage Si.

automobile friction material on pin on disc

They have found that hardness, bending and

apparatus, Daud et al (54) found that friction

fatigue tests indicated that reinforcing the

coefficient of composite disc decreased with

Al-alloy

applied load. Kaynak and Boulu (55) found

matrix

with

SiC

particulates

that

wear

rate

composites

and

sliding

friction

against

strength

that by reinforcing the Al-alloy matrix with

and fatigue resistance with increasing

SiC particulates improved the hardness,

content of SiC particulates. Walker et al(50)

flexural strength and fatigue resistance with

have

increasing content of SiC particulates

improved the hardness, flexural

found

the

predominant

wear

mechanism during lubricated sliding of 2124


& 5056 aluminum alloys is mild wear by

CONCLUSIONS

abrasion. The introduction of a harder

The properties of AMCs have been widely

reinforcing second phase to the matrix

examined and would appear to offer several

resulted in an improvement

major advantages, namely-

of

wear

resistance for both alloys. Mondal & Das


(51) have found that wear rate in Al

30% times that of cast Iron and better

composites increases linearly with applied

wear characteristics.

load irrespective of the material and abrasive


size. Withers & Tilakratna (52) reported that

iron.

heat dissipation characteristics, better liner

behavior of Al-Si/SiC composites against


automobile brake pads Uyuru et al (53)

An MMC disc could be 60 % lighter


than an equivalent cast iron component.

four tenths of the weight of similar size of


CI brake drum. In the study of the wear

The thermal conductivity of AMC can


be two or three times higher than cast

al-MMC automotive brake drums have high

wear characteristics and weight less than

The friction coefficient of AMC is 25-

The Thermal Diffusivity, which is the


rate of heat dissipation compared to that
of storage, is four times that of cast
iron.

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Journal of Engineering Research and Studies

the

18.

performance of which depends on the nature

19.

Clearly

an

impressive

material,

of the composite dispersion.

20.

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