DRY SLIDING WEAR STUDIES OF

COPPER-BASED POWDER
METALLURGY BRAKE MATERIALS

PRESENTED BY :
AAKASH RAJEEVAN
S1 AMD
ROLL NO.1
 CONTENTS
 INTRODUCTION
 POWDER METALLURGY PROCESS
 EXPERIMENT
 SAMPLE PREPERATION
 TESTING PROCEDURE
 EQUATION USED
 RESULT AND DISCUSSION
 CONCLUSION
 FUTURE WORK
 REFERENCES
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INTRODUCTION

 Cu-based matrix material produced by Powder Metallurgical

method offers excellent heat conductivity and higher anti-wear
properties.
 Wear on train brake pads resulted in both economical and safety
issues.
 Objective : To study the effect of increasing Sintering
temperature on mechanical and tribological characteristics.
 This research is restricted to dry (unlubricated) conditions.
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POWDER METALLURGY

STEPS IN POWDER METALLURGY

 Powder Production

 Mixing

 Compaction

 Sintering

 Secondary Operations

Fig. 1 Powder metallurgy process

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ADVANTAGES

 Efficient material utilization and close dimensional tolerances.

 Good surface finish and complex shapes possible.
 Hard materials used to make components
 Wide variety of materials
 Parts with controlled porosity can be made.

LIMITATIONS
 High cost of powder material & tooling.
 Less strong parts than wrought ones.
 Less well known process.
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EXPERIMENT
Friction and wear characteristics of Cu-based brake material while
varying the Sintering temperature.

Samples were Sintered at temperatures (850, 900 and 950 °C)

Sintering temperature above 950°C is expected to affect the properties
materials
Scanning Electron Microscope (SEM) and Optical Microscope (OM)
were used.
Pad-on-disk high pressure tester.
Vickers scale for Hardness Value.
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SAMPLE PREPARATION
SELECTION OF POWDER MATERIALS
Category Matrix Lubricants Alloying elements
component
Elements Cu Graphite MoS2 Mn Sn Fe SiO2
Weight(%) 50-60 5-10 10-15 1-5 1-2 10-12 8-10

Table 1 Chemical compositions of brake materials (weight %)

MIXING

 In a Double Cone mixture

machine.

 At 150 rpm for 9 hours.

Fig. 2 Double Cone Mixer

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COMPACTION
 Compacted in a Hardened
steel die using a hydraulic
compacting machine.

 Under a pressure of 650

Mpa.

Fig. 3 Hydraulic compaction machine

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SINTERING
For 90 minutes at 850-950 °C at 0.01 MPa constant Pressure.

Fig. 4 Micro structure of sintering

Component is dipped into hot oil to control level of porosity.

Resulting rectangular bar of thickness 5mm is cut in to 14x14 mm
test specimen.
9 pair of specimens were prepared.
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TESTING PROCEDURES
CHARACTERIZATION TEST

Hardness Value :
Measured after Sintering using
Digital micro hardness tester and taken in
Vickers scale.

Fig.5 Digital Hardness Tester >

Density :
 Measured after sintering
Weight is measured by digital weighing
machine

Fig. 6 Digital weighing machine >

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PERFORMANCE TEST
 Determination of coefficient of friction.
 Friction force.
 Wear loss and type of wear.
Parts are
Control Unit
Monitoring Unit
Disk and Motor
Sample holder
 temperature
control unit
Fig. 7 X-MSM Constant Speed Friction Material Tester
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FRICTION TEST RIG

2 specimen pressed against rotating cast iron disk

Rotated for 5000 revolutions (sliding velocities of 7.54 ms-1)
 Sample holder modified with surface area 14x14 mm2 and
contact pressure to 3.13 Mpa.
Performed at temperatures of 150, 200, 250, 300 and 350 °C
Temperature controlled by circulating water supply
Tester obtained the friction coefficient data automatically
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EQUATIONS USED
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TABULATED RESULT

Sintering temperature(0c) 850 900 950

Density of bulk material(g.cm-3) 7.97

Density of specimen, ρ (g.cm-3) 6.51 6.71 6.85

Porosity, P (%) 17.5 15.8 14

Micro hardness(HV) 272 287 304

Wear number Wn 7.8 9.9 10.3

Wear coefficient, k 1.54 1.66 0.44

Coefficient of friction 0.336 0.343 0.404

Table 2 Tabulated results

 RESULTS AND DISCUSSION 13

MECHANICAL PROPERTIES
(1)Relationship between porosity and sintering temperature

Fig. 8 Relationship between porosity and sintering temperature

Porosity decreases with increase in Sintering temperature.

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Increment in temperature % decrement in porosity
500c 9.71

1000c 20.59

Table 3 Decrement in porosity

Average porosity of 15.73% in the composite.

This result is within the PM materials porosity range (10–35%)
Reason:
Self-diffusion and inter-diffusion of atoms

Low melting point materials (such as Sn) in liquid phase

will fill some pores
(2)Relationship between hardness and sintering temperature 15

Fig. 9 Relationship between hardness and sintering temperature

 Hardness is proportional to Sintering temperature.

 Hardness increased 5.51% by increasing sintering
temperature as 500c and 11.76% by increasing 1000c
 TRIBOLOGICAL BEHAVIOUR 16

Concerned about Coefficient of friction (p), wear coefficient (k), Wear

Number (Wn) and Wear surface.
Relationship between Wear Number and Coefficient of wear with
Sintering Temperature

Fig. 10 Relationship between Wear Number and Coefficient of wear with Sintering Temperature
Wear coefficient decrease and wear number increased with
sintering temperature
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Wear number increased 26.92 % by increasing sintering

temperature as 500c and 32.05 % by increasing 1000c
Wear coefficient increased 7.79% by increasing sintering
temperature as 500c and decreased 70% by increasing 1000c
Wear number is wear resistance level of the design material
Wear coefficient used to measure correlate the wear of materials
Less wear number and wear coefficient shows less wear rate
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Relationship between coefficient of friction sintering temperatures.

Fig. 11 Relationship between coefficient of friction sintering temperatures.

 Coefficient of friction increases with increase in Sintering

temperature.
 Coefficient of friction increased 2.08% by increasing sintering
temperature as 500c and 20.23% by increasing 1000c
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CONCLUSION
Porosity reduced at higher Sintering temperature, average value
15.73%
wear coefficient (k) inversely proportional to Sintering temperature.
At 9500c temperature k decreased 70% than 8500c
Coefficient of friction (µ) proportional to Sintering temperature.
at 9500c temperature µ increased 20.23% than 8500c
Reason :
(1)Self-diffusion and inter-diffusion of atoms
(2)Low melting point materials (such as Sn) in liquid phase will
fill some pores
(3) graphite entrapped in the pores may then lead to
strengthening
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SCOPE FOR FUTURE WORK

Effect of increasing Sintering temperature on mechanical

and tribological characteristics.

Mechanical and tribological characteristics also

depends
 compacting pressure,
 types and amount of lubricant added
 Sintering time and pressure

Fe based alloy or other Cu based alloys

Semi metallic friction material
Nonmetallic matrix friction material
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REFERENCES
[1] Chandrasekaran, M., and Sngh, P., 2010, “Sintered Iron-Copper-Tin-Lead Antifriction
Materials-Effect of Temperature [J],” Mater. Sci. Eng., A, 292, pp. 26–33.
[2] Kim, J. W., Kang, B. S., Kang, S. S., and Kang, S. J. L., 2008, “Effect of Sintering
Temperature and Pressure on Sintered and Friction Properties of a Cu Base Friction
Material [J],” PIM Int., 20(3), pp. 185–191.
[3] Kennedy, F. E., Balbahadur, A. C., and Lashmore, D. S., 1997, “The Friction and Wear
of Cu Based Silicon Carbide Particulate Metal Matrix Composites for Brake Applications,”
Wear, 203/204, pp. 715–721.
[4] Yao, P., Sheng, H., Xiong, X., and Huang, B., 2007, “Worn Surface Characteristics of
Cu-Based Powder Metallurgy Brake for Aircraft,” Trans. Nonferrous Met. Soc. China, 17,
pp. 99–103.
[5] Moustafa, S. F., El-Badry, S. A., Sanad, A. M., and Kieback, B., 2002, “Friction and
Wear of Copper-Graphite Composites Made With Cu-Coated and Uncoated Graphite
Powders [J],” Wear, 253, pp. 699–710