Design and optimization of non asbestos brake pad using sea shell in phenolic resin

Abstract

newline Brake is a critical system of every automobile, in which the friction lining materials wears progressively to provide the necessary braking effect to stop or control the automobile. They play very important role sacrificing own materials loss. Asbestos and its composites, which have strong tribological and mechanical qualities, have been utilized for decades with a variety of compositions. In the present work initially, a novel asbestos-free friction lining materials was developed using sea shell powder with phenolic resin as the binder, and alumina, metal filings, and graphite as fillers. There were no pollutants left after one week of washing and drying in the sun. Oven curing at above 100oC for five hours (5 hrs) was done to remove excess moisture out from sea shells. The pulverized seashell diameter of 125 and#956;m, phenolic resin, carbonate, metal filings, and graphite were used to make each sample, which was then evaluated in accordance with the ASTM D 4703-03 Chemplastica standard. The non-asbestos brake pads were developed with sea shell powder (SS) as filler with other four constituents; designated as SS20, SS25, SS30 and SS35 and compared with commercial brake pad material. All the four materials were subjected to physical, chemical, Thermal Gravimetric-Differential Thermal Analysis (TG-DTA) studies and mechanical properties determination. Inclusion of sea shell in phenolic resin played a vital role in enhancing the various properties like density, hardness, acetone extraction and compressive strength in an effective manner. The correlation between composite properties and its wear rates were very good with the R2 values were greater than 0.9, indicating more than 90% correlation accuracy.