A Comparative Study On-Dynamometer Performance Evaluation of Fly Ash Containing Non Ferrous Organic and Low-Metallic Disc Brake Pads for Passenger Vehicles and Thereby Promoting a Very Cheap Inorganic Filler Available in Abundance (SAE Paper 2020-01-1613)

A number of functional and non- functional fillers are invariably used for friction material composites. In recent years disposal of fly ash has been a big challenge due to low availability of damping sites. Current work investigates the characterization of Low -metallic and Organic composites made with fly ash with variable concentrations and evaluated for braking performance (SAE J2522) & wear (SAE J2707) on a brake inertia dynamometer. Composites have been characterized for their physical, thermal, mechanical and tribological performance. Low-metal based composites (LMBC) have shown better thermal resistance than non-ferrous organic formulation based composites (NFOC). Mechanical properties such as hardness, shear strength and compressibility have been found to be similar for both the composites. NFOC composites have shown better wear resistance while acquiring slightly lower coefficient of friction values. Load-speed sensitivity of the composites has been further investigated to simulate the on-road conditions. Topographical variations and their possible roles in controlling the tribological performance have been characterized by worn surface morphology. Counter-face friendliness of the brake pads have been investigated by scouring test and found to be better for non-ferrous organic formulation based composites. The study concludes that fly ash can be used a cheap inorganic filler in low met and organic composites.