This study compares the effect of the addition of two types of lubricants on the dry sliding behavior of a simplified Cu-free phenolic resin-based composite material. The lubricants were commercial graphite and exfoliated graphitic carbon nitride (codenamed: TEX6). The graphite particles were rounded and of ‘flaky’ character. The TEX6 particles were not only flaky, but also irregular in shape, and ‘fluffy’. Both lubricants were added individually in the basic formulation and subjected to dry sliding tests on pin-on-disc testing equipment in mild conditions and against a grey cast-iron counterface. The tests with TEX6 observed a stable steady state in the friction coefficient (CoF) with lower scatter and lower average friction coefficient and pin wear magnitude when compared to samples containing graphite. Additionally, the worn surfaces of the TEX6-containing samples had extremely smooth, compact, and continuous secondary plateau coverage when compared to the graphite-containing samples. The counterface paired with the TEX6-containing samples observed much lower abrasive action compared to the graphite-containing samples. Through the wear testing and further evaluation of the secondary plateaus, the possible addition of TEX6 as a lubricant in friction material composition was explained, making it a promising component for automotive braking applications.

Dry sliding wear tests and corresponding particulate matter (PM) analysis were conducted on a newly developed SiC-graphite-based composite friction material, paired with two types of HVOF counterface/discs: WC-CoCr and WC-FeCrAlY coatings, with a conventional martensitic stainless steel counterface as a reference. The trials were conducted on a pin-on-disc testing equipment at room temperature and a constant sliding velocity and contact pressure of 7 m/s and 0.5 MPa, respectively. The coefficient of friction (CoF) curves with the uncoated disc exhibited considerable fluctuations. On the other hand, the coated discs featured an increase in the CoF at the beginning of the tests, followed by either a continuous reduction until the end of the testing duration or the attainment of a steady state regime. The pin wear and emissions with both coatings were appreciably lower when compared to the trials with the uncoated disc. The evaluation of the friction layer observed a significant contribution of the counterface for all the pairings. The PM analysis was conducted on the particles that were lying in the range of 10 μm and 2.5 μm on a scanning electron microscope (SEM), and particles from 2.5 μm and 1 μm on transmission electron microscope (TEM), with an emphasis on the particles that were detached from the pin surface and friction layer to explain the wear mechanisms for each pairing. Through this, the need for the proper selection of both friction material and counterface to avoid the emission of harmful compounds in the environment was highlighted.

The aim of our research was to indicate the suitability of metallurgical slags (two blast furnace slags and one steel furnace slag) as the components of Cu-free friction materials. The base mixture consisted of nine components including phenolic resin, graphite, tin sulphide, steel and aramid fibers, iron powder, a mixture of barite with calcite, and vermiculite. To this base mixture, the slags with a particle size below 0.1 mm were added individually in the amount of 20 wt.%. A base friction mixture with alumina in the amount of 20 wt.% represented the reference. Samples for the friction-wear tests were produced in the form of pins by hot press molding. The prepared pins were tested using a pin-on-disc tester in a drag mode at the pressure of 1 MPa and a constant sliding speed of 1.51 m/s for 90 min. The samples with slags exhibited slightly lower values of steady-state friction coefficient compared to the reference composite with alumina, and at the same time produced lower wear particle emissions. The particle concentration was reduced for the samples with slowly cooled blast furnace and steel furnace slag. The results obtained indicated steel furnace slag as a promising component of Cu-free friction composites.

With recycling and reuse in mind, this study explores the possibility of the utilization of waste generated during the plasma cutting operations to produce aluminum products in a commercial friction material formulation for car braking applications. The as-received waste, analyzed in the form of a powder, was subjected to various characterization techniques to obtain its composition and phase constituents. The friction, wear, and emission analyses were organized in two ways: the first part focused on the selection of the most suitable waste content in the friction material formulation—10, 15, and 20 wt.%—tested in the form of pins, using a pin-on-disc tribometer. The second part evaluated the most suitable content in the formulation in the form of coupons on a subscale dynamometer to comprehend its friction and emission characteristics in a more complex scenario. Through the pin-on-disc analysis, it was seen that the 10 wt.% of waste in the formulation provided permissible friction and wear behavior, and similar emission magnitude and secondary plateau characteristics were seen, as compared to the reference composition. Similar results were recorded on the subscale dynamometer at mild braking conditions. At ‘severe’ testing conditions, a different trend was observed. Through this analysis, the possibility of the addition of this kind of waste in friction material composition has been evaluated deeply, paving a path for further analysis and possible implementation.

With sustainability dominating the industry, recycling the generated waste from different processes is becoming increasingly important. This study focuses on recycling waste generated during aluminum anodizing waste (AAW) in friction material formulations for automotive braking applications. However, before utilization, the waste needs to be pre-treated, which mainly involves drying. Hence, four different industrial drying methods were studied to dry the AAW, and the corresponding characteristics were observed by evaluating its residual humidity and crushability index. The waste powders were further characterized using FT-IR and SEM/EDXS to understand their constituents. The initial analysis showed that the waste subjected to the drying process P2 and P1 with the lowest final humidity fetched the most desirable results, with P1 having the simpler drying procedure. The AAW powders were added in a commercial friction material formulation at 6 and 12 wt.% and subjected to friction, wear, and non-exhaust particulate matter analysis. The worn surfaces were analyzed using SEM/EDXS evaluation to understand the extension and composition of the deposited secondary contact plateaus. It was seen that the 12 wt.% addition of waste processed using the P1 technique provided the most satisfactory friction, wear, and emission characteristics, along with expansive secondary contact plateaus with a good contribution of the waste in its formation. This study showed a good relationship between the processing method and a formulation’s tribological and emission characteristics, thereby paving the way for using this drying method for other waste requiring pre-treatment.