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Brake linings have complex microstructure and consist of different components. Fast growing automotive industry requires new brake lining materials to be developed at considerably shorter time periods. The purpose of this research was to generate the knowledge for optimizing of brake friction materials formula with mathematical methods which can result in minimizing the number of experiments/test, saving development time and costs with optimal friction performance of brakes. A combination of processing methods, raw materials and testing supported with the Artificial Neural Network (ANN) and Taguchi design of experiment (DOE) allowed achieving excellent results in a very short time period. Friction performance and wear data from a series of Friction Assessment and Screening Test (FAST) were used to train an artificial neural network, which was used to optimize the formulations. The averaged COF, COF variation and wear were used as the output parameters.

Copper and copper alloys are widely used in friction materials such as brake pad formulations as one of key ingredients by providing good thermal conductivity and high temperature friction stability to achieve desired friction performance, fade and wear resistance. However, the use of copper or copper containing material is being restricted in brake pads due to environment and health concerns. Extensive works have been made to explore the copper substitutes but most of these efforts became ineffective and failed with issues either thermal fade or excessive pad/rotor wear. In this paper, friction and wear responses were examined when a metallic composite material was used as the copper substitute in NAO and Low-met brake formulations where the copper and copper alloys were added 8% and 22% respectively.

Besides elimination of copper, the eco-friendly brake materials are developed using geopolymer matrix and natural fibers to replace phenolic resin and synthetic fibers, respectively. The objectives are to diminish i) the amount of volatile organic compounds (VOCs) being released from the brake materials when subjected to temperatures higher than 300 °C; and ii) release the potentially hazardous wear debris particles to the environment. Brake materials were fabricated in university and tested using SAE J2430 test procedure and full scale automotive brake dynamometer (Dyno). Dyno test results indicate that the average friction level of the eco-friendly Cu-free materials (µ ∼ 0.30 to 0.33) was only slightly lower when compared to the baseline material containing Cu (µ ∼ 0.35). All tested materials have passed the Brake Effectiveness Evaluation Procedure (BEEP).

The purpose of this research study was to develop Cu-free automotive brake materials. Model brake material samples were manufactured and subjected to full scale automotive brake dynamometer (Dyno) tests using SAE J2430 test procedure. The SAE recommended J2430 test procedure provided the necessary data for the Brake Effectiveness Evaluation Procedure (BEEP) by the Brake Manufacturers' Council. The Dyno results indicate that the friction level of the all four Cu-free samples was similar to the baseline material. All tested brakes have passed the Brake Effectiveness Evaluation Procedure (BEEP). The average effectiveness of Baseline (BL), GT1, GT2, T401 and T402 samples is 0.32, 0.31, 0.30, 0.31 and 0.31, respectively. The Dyno results show that the Cu-free samples had similar or better performance compared to the baseline material as the temperature of the brake increased in the fade section. However, the Cu-free samples exhibit slightly higher wear rate in Dyno tests.