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Ceramic Materials Engineering, University of Bayreuth, Ludwig-Thoma-Str. 36b, 95447 Bayreuth, Germany
Center for High Temperature Materials and Design (HTL), Bayreuth, Fraunhofer ISC, Germany
Audi AG, Ingolstadt, Germany
d
Engineering Design and CAD, University of Bayreuth, Universittsstrae 30, 95447 Bayreuth, Germany
b
c
a r t i c l e
i n f o
Article history:
Received 27 January 2016
Received in revised form 22 April 2016
Accepted 24 April 2016
Available online 2 May 2016
Keywords:
Friction
Tribology
C/SiC
Ceramic brakes
Dynamometer
CMC
a b s t r a c t
Ceramic matrix composites (CMC) are promising materials for friction applications. Typically, C/SiC rotors
are combined with organic pads (Low Met). Within this work, two types of CMC brake pads were studied,
C/SiC SF as well as C/SiC SF 11Coke with 11 vol.% coke as ller, accompanied with the Low Met reference
pads. Small brake pads (400 mm2 ) were applied on a lab-scale and larger pads (12,000 mm2 ) on a fullscale inertia dynamometer. In both cases, the corresponding rotor was a C/SiC disc with a SiC-rich friction
layer. Sliding speeds up to 42.6 m/s and braking pressures up to 8 MPa were applied. The smaller CMC
pads show lower wear and higher coefcient of frictions (COF), compared to the reference. This frictional
behavior was conrmed on the full-scale dynamometer with mean COFs up to 0.45. However, the wear
of the large C/SiC pads was somewhat higher on the full-scale dynamometer.
2016 Elsevier Ltd. All rights reserved.
1. Introduction
In order to overcome the thermal and mechanical limits of conventional organic- or metallic-based braking materials, ceramic
matrix composites are promising candidates. C-ber reinforced
carboncomposites (C/C) are state of the art in aircraft brake systems and in formula one race cars. The ber reinforcement enables
a suitable damage tolerance and favorable mechanical strengths.
Low densities (<2 g/cm3 ) make them very suitable for light weight
applications. However, C/C is not a lifetime material, because of its
insufcient oxidation resistance, the low COFs in humid conditions
and at temperatures below 200 C [15]. Therefore, researchers
from the German Aerospace Centre (DLR) in Stuttgart developed
C-ber reinforced SiC (C/SiC resp. C/C-SiC) for brake applications
in the early 1990s [1,69]. This technology is a real spin off from
thermal protection systems of space craft to terrestrial applications and the composites can be efciently manufactured by the
liquid silicon inltration process (LSI). The ceramic material was
evaluated for high performance emergency brakes in elevators and
conveying systems and also for service brakes in passenger cars
and high speed trains [11]. At the beginning of this century, several
Corresponding author.
E-mail address: nico.langhof@uni-bayreuth.de (N. Langhof).
http://dx.doi.org/10.1016/j.jeurceramsoc.2016.04.040
0955-2219/ 2016 Elsevier Ltd. All rights reserved.
3824
Table 1
The constituents of the brake pads [42].
Disc material
Pads materials
C/SiC
Low Met
C/SiC SF
C/SiC SF 11Coke
Metallic components (bers and particles from steel, brass, bronze, copper)
Amorphous C-bers
Amorphous C-matrix
SiC
Silicon
Porosity
Amorphous C-bers
Amoprhous C-matrix
Coke
SiC
Silicon
Porosity
Amorphous C-bers
Amorphous C-matrix
SiC
Silicon
Unknown
Porosity
Table 2
Test matrix on the lab-scale test rig.
Speed Series (p = 2.44 N/mm2 )
Rotating Speed in m/s
Braking Time in s
3.4
17.4
42.6
2.7
2.7
2.7
Cycles
113
22
9
Friction energy in MJ
2
2
2
8.3
42.5
104
Braking Time in s
Cycles
Friction energy in MJ
12
2.7
22
22
2
2
9.4
42.5
power intensities (W/mm2 ) can be realized, are rarely found in literature [28,31]. Very few works are dealing with high speeds above
25 m/s [21,28,31,32]. Further investigations show the inuences of
silicon, silicon alloys and additives on the tribological properties.
The COFs decrease at higher speeds above 20 m/s and the wear rates
increases signicantly [17,18,21,3133,35,39,40]. SiO2 , derived by
the oxidation of Si and SiC, can be found on the frictional surfaces
above 400 C [20,21,28,32,41].
Within the current study, the tribological behavior of C-short
ber reinforced ceramics on a lab-scale and a full-scale test rig are
investigated. The chosen pad-on-disc setup consists of a harder,
which means a SiC-rich friction layer bearing C/SiC brake rotor
(diameter 380 mm), on softer less SiC- resp. coke containing C/SiC
brake pads. In order to enhance the tribological behavior of the
C/SiC materials, coke as a solid lubricant was added. Lower stiffnesses, obtained in mechanical tests, show the softening effect
of coke and the potential for a further improvement of the properties of the C-ber reinforced ceramic brake pads, compared to
conventional friction materials like Low Mets or Semi Mets.
The ceramic materials were studied at sliding speeds up to
42.6 m/s and braking pressures up to 8 MPa. Furthermore, the friction and wear mechanisms were discussed and summarized in a
preliminary model.
coke was mixed with the phenolic powder and C-ber bundles
subsequently.
Three types of pad materials were studied:
3825
Fig. 1. Initial friction surfaces of C/SiC pads with 6 mm carbon short bers (400 mm2 ).
Table 3
Overview of the AK-Master test (SAE J2522); The sliding speed is calculated, regarding to the mean friction radius of the pads (r = 0.152 m).
No.
AK-Master Sections
Conditions
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Green Effectivness
Burnish
Characteristic Check
Speed-Pressure Sensitivity
Speed-Pressure Sensitivity
Speed-Pressure Sensitivity
Speed-Pressure Sensitivity
Speed-Pressure Sensitivity
Characteristic Check
Cold Braking
Motorway Braking
Characteristic Check
1st Fading
1st Recovery
Pressure Sensitivity
Temperature Sensitivity
Pressure Sensitivity
Characteristic Check
2nd Fading
Characteristic Check
3826
Table 4
Bulk density, open porosity and the composition of the applied pads, ns = not specied.
Bulk Density [g/cm3 ]
Disc material
C/SiC
2.45
ns
Pad materials
Low Met
C/SiC SF
C/SiC SF 11Coke
4.50
2.00
1.94
25.0
1.0
2.1
Fig. 3. (a) Geometry of the C/SiC ceramic brake pad (frictional surface = 12000 mm2 ); (b) experimental setup (brake disc and calliper) in the full-scale inertia dynamometer
(Audi AG).
Fig. 4. Microstructure of the ceramic pads (cross sections) before braking (optical microscope images); (a) C/SiC SF; (b) C/SiC SF 11Coke.
Fig. 5. Speed and pressure series on the lab-scale test rig; (a) Dependence of COF on the speed at constant pressure; (b) Dependence of COF on the pressure at constant
speed.
The AK-Master test contains high and low speed braking sections as well as different braking pressures. The COFs and the
3827
Fig. 7. AK-Master test for Low Met reference on the ceramic disc; dotted lines: max.
and min. COF , straight line: mean value; highlighted: Section 8 and 11 (for detailed
test conditions, see Table 3).
Fig. 6. Wear rates after the pressure series (v = 17.4 m/s, p = 0.54 resp. 2.44 N/mm2 )
resp. the speed series (p = 2.44 N/mm2 ; v = 3.4; 17.4 and 42.6 m/s) for all brake pairs,
determined after each series, the speed resp. the pressure series.
Fig. 8. AK-Master test for C/SiC SF on the ceramic disc; dotted lines: max. and min.
COF , straight line: mean value; highlighted: Section 8 and 11 (for detailed test
conditions, see Table 3).
Fig. 9. AK-Master test for C/SiC SF 11Coke materials on the ceramic disc; dotted
lines: max. and min. COF , straight line: mean value; highlighted: Section 8 and 11
(for detailed test conditions, see Table 3).
v = 3.4; 17.4 and 42.6 m/s). C/SiC SF shows the highest wear rates
with 13 105 mm3 /J and C/SiC SF 11Coke the lowest wear with
1.0 105 mm3 /J. Due to the addition of coke, the ceramic pads
becomes softer. It show 25% less stiffness compared to C/SiC SF.
Furthermore, coke particles are less brittle and more exible than
the other phases within the ceramic pads. Therefore, the real contact and the COF increases simultaneously with a decreasing wear
rate.
3.2. COFs and wear on a full-scale inertia
dynamometerAK-Master test
The tribological behaviors of the full-ceramic materials as well
as the Low Met reference were studied during the AK-Master tests.
COFs were measured continuously, as well as the temperatures of
the friction materials. The amount of wear was determined after
the tests by measuring the thickness changes. The results, obtained
in the AK-Master tests, show the consistent COF between 0.28 and
0.44 for the reference Low Met material on the ceramic rotor (Fig. 7).
Immediately, within the rst AK-Master section the full-ceramic
couples show one favorable property. The COF for this green effectiveness cycle is remarkably higher (0.45) compared to the Low
Met pads (0.3). The mean COF of the C/SiC SF material (0.39) is on
the same level compared to the state of the art Low Met material (Figs. 7 and 8). For the C/SiC 11Coke material, the mean COF
increases signicantly up to 0.45 (Fig. 9). The behavior is more balanced compared to C/SiC SF and on a higher COF level, independent
of the conditions within the AK-Master test sections. Furthermore,
3828
different, which are ve for the small pads and about 24 for the
larger pads. That mean, that the small pads exhibit more particles
close to the outer surface, which can be abraded or sheared off
more easily in comparison to the larger ceramic materials. Hence,
porous materials, like the Low Met reference degrade more and
show higher wear rates on the lab-scale test rig. The reliability of
the obtained results on a lab-scale test rig, rises with an increasing
of the thermomechanical stability of the selected friction materials.
3.4. Friction and wear mechanisms in the full-ceramic brake
systems
Fig. 10. Wear of the Low Met and both ceramic pads.
In order to summarize and visualize the observed wear and friction mechanisms, the preliminary approach [31], can be extended
signicantly (Fig. 11). Due to the examination of the frictional
surfaces, the cross sections, the surface roughnesses and the
temperatures, we can identify several key mechanisms for the
full-ceramic brake systems. The focus was on the formation of a 3rdbody (friction layer resp. contact plateaus), which can be formed
between the ceramic disc (1st-body) and the ceramic brake materials (2nd-body). In general, the 3rd-body is required to enable stable
and high COFs in brake systems.
Following remarks, regarding the friction and wear mechanisms
of the full-ceramic brakes systems can be made:
No wear was detectable for the hard resp. SiC-rich C/SiC rotors.
A 3rd-body was found on the surface of C/SiC SF and C/SiC SF
11Coke (Fig. 12).
The 3rd-body covers a larger surface for the C/SiC SF 11Coke
material.
Due to the presence of free silicon in the full-ceramic friction
couple, an adhesion-abrasion mechanism can destroy the local
3rd-body, which can be observed by deep grooves on the C/SiC
SF material and the generation of high wear rates (Figs. 12 and 14).
The presence of coke and fewer silicon changes the observed wear
mechanisms for the C/SiC SF 11Coke pads.
The lower Si-content in C/SiC SF 11Coke prevents formation of
adhesive-abrasive wear spots/peaks and deep grooves and generated a higher contact area and COF.
The material gets softer as a bulk (lower stiffness) and the surface is able to trap wear particles due to coke as a friction modier.
More exible coke particles are able to increase the real contact
area during braking, accompanied with higher COFs, lower wear
rates and less COF uctuations.
3.5. Abrasion
Several hard and rough Si-SiC peaks on the disc surface (Fig. 13)
are responsible for the deep grooves on the surface of the C/SiC
SF materials (Figs. 12a and 14a). The deep grooves are no longer
detectable, if coke is added to the pad material (Figs. 12b and 14b).
The low content of silicon in the C/SiC SF 11Coke material prevents
the formation of the roughness peaks on the corresponding C/SiC
rotor. Hence, the lack of abrasive wear causes much lower wear
rates for C/SiC SF 11Coke compared to C/SiC SF.
The surface roughness of both ceramic pads are shown and analysed by confocal microscopy in Fig. 14 resp. Table 6 It can be
concluded, that the maximum roughness of both materials is similar, but the C/SiC SF 11Coke material shows spots resp. plateaus
with signicantly lower roughnesses (Table 6). Due to these many
contact plateaus the wear resistance of C/SiC SF 11Coke is higher
compared to C/SiC SF.
Furthermore, for the dense C/SiC SF material without coke, there
are no possibilities to prevent a three body abrasion according to Ref. [34], which means the abrasion, which is caused by
hard SiC wear particles between both frictional surfaces. Hence,
3829
Fig. 11. Model which sums up the observed friction and wear mechanisms for the full-ceramic brake systems, C/SiC SF and C/SiC SF 11Coke.
Fig. 12. Frictional surfaces (SEM images, topography contrast); (a) C/SiC SF with partially deep grooves due to abrasion; (b) C/SiC SF 11Coke; SD = sliding direction.
Fig. 13. Frictional surface of the C/SiC rotor after braking on the lab-scale rig (counterpart: C/SiC SF); SD = sliding direction (Fig. 5a); (a) top view; back scattered SEM image;
(b) cross section (optical microscope) [33].
Fig. 14. Surface roughness/topography; areas denoted measured in Table 6 (a) C/SiC SF; (b) C/SiC SF 11Coke.
3830
Table 5
Detailed comparison of the tribological tests on the lab-scale and the full-scale test rig; TDisc measured on the surface, TPads measured on the backside.
Lab-scale test rig
Pad type
COF
TMaxDisc in C
TMaxPads in C
COF
Wear in mm
TMaxDisc in C
TMaxPads in C
0.200.42
0.240.63
0.280.64
4.4
7.4
1.3
530
380
440
140
610
370
0.280.44
0.270.58
0.310.49
0.58
1.48
0.8
800
850
800
300
500
450
Table 6
Surface and prole roughness according to the areas in (Fig. 14), Sa resp. Ra = average roughness, Sp resp. Rp = max. peak height, Sv resp. Rv = max. valley depth.
Surface roughness and (StDev) in m C/SiC SF resp. C/SiC SF 11Coke as received (n = 5)
Sa = 1.3 (0.1)
Sp = 7.1 (0.9)
C/SiC SF braked (n = 3)
Sv = 10.3 (3.3)
C/SiC SF 11Coke braked (n = 3)
e.g.
Area 1
Sa
3.3
Sp
11.7
Sv
16.6
e.g.
Area 1
Sa
3.1
Sp
10.1
Sv
32.3
Area 2
3.5
18.8
18.5
Area 2
1.4
5.8
18.7
Area 3
Mean
4.8
3.9
14.6
15
28.3
21.1
Area 3
Mean
1
1.8
3.1
6.3
4.8
18.6
Rp
9.9
10.1
10.8
12.6
10.9
Rv
13.3
13.9
14.3
15.1
14.2
deep grooves evolve and the potential contact area, which could
enhances the friction forces, decreases. The coke containing material has the ability to avoid theses abrasion mechanisms, by
trapping these particles inside of the soft coke akes.
3.6. Adhesion
In conjunction with the abrasion, the adhesion has to be
discussed. Adhesion between the C/SiC rotor and C/SiC SF pad
accompanied by material transfer occurred due to the free silicon
on both frictional surfaces. Silicon welds together during friction
and can incorporate hard SiC wear particles (Fig. 13b). Speeds
above 20 m/s and temperatures above 400 C enable this observed
phenomenon, because of the brittle to ductile transition of silicon
[33,3638] and a presumably incorporation of the SiC wear debris.
Furthermore, the new evolved welding contacts start to transfer
Si from the C/SiC SF pads to the C/SiC rotor, where the silicon is
bonded stronger and the peaks continuously grow the longer a
brake test last. Due to the higher SiSiC content, the thermal conductivity of the rotor is signicantly higher (>20 W/mK) compared
to the pads (<10 W/mK). Therefore, after the brittle to ductile transition, the Si within the C/SiC SF pads gets softer and is transferable
more easily than from the colder opposite direction. The silicon
from the rotor is derived from the SiSiC friction layer. This friction
layer is formed during the siliconization and its microstructure is
similar to a monolithic SiSiC ceramic with only few C-bers. On
the one hand, the silicon matrix with this friction layer is homogenously distributed over the whole surface of the friction layer. On
the other hand, silicon in the pads is not so well distributed and can
be found in spots or small cracks resp. aggregates in the dimension
of 1050 m width surrounded by SiC and mainly carbon. Therefore, it is more realistic to assume, that silicon is transferred from
the pads towards the rotor. Lower forces are required to pull the
silicon out of the pads, compared to the silicon from the rotor. This
unfavorable mechanism, is the reason for the partially removed
e.g.
Line 1
Line 2
Line 3
Line 4
Mean
Ra
1.8
1.3
1.8
1.8
1.7
Rp
3.9
4
6.4
4.1
4.6
Rv
5.8
3.5
4.6
7.9
5.5
3831
Fig. 15. Frictional surfaces (SEM images, topography contrast); (a) C/SiC SF with partially removed friction layer due to adhesion; (b) C/SiC SF 11Coke; SD = sliding direction.
Fig. 16. EDX-analysis of the C/SiC disc surface indicate the presence of oxygen, besides of Si and C.
Fig. 17. Cross sections (optical microscope) after braking; (a) C/SiC SF; (b) C/SiC SF 11Coke.
and the rotor, adhesive-abrasive wear were observed and are crucial for the C/C-SiC SF materials.
Due to the addition of coke (C/SiC SF 11Coke) as a solid lubricant
the stiffness of the material decreases to 25%. Soft and exible
coke particles within C/SiC SF 11Coke increase the real contact
area, accompanied with higher COFs, lower wear rates and less
COF uctuations. The average COFs rises from 0.39 up to 0.45 (AKMaster) and the wear rate drops from 7.4 105 mm3 /J down to
1.3 105 mm3 /J for the lab-scale tests and during the AK-Master
from 1.48 to 0.8 mm thickness loss.
In order to make some conclusions we have to point out some
statements after this study.
3832
Without any modications of the C/SiC SF materials, the competiveness of the full-ceramic approach is limited, compared the
organic references on the ceramic rotor.
The study shows, that it is favorable to combine stiff rotors with
softer ceramic pads (soft-hard approach)
By the addition of friction modiers, like coke, the friction and
wear behavior can be tailored to the desired application and performance.
The partially started replacement of metallic or organic based
friction materials can be continued and extended towards many
applications in the eld of high temperature light weight design.
Lab-scale test rigs are suitable for screening tests, if the applied
speeds and pressures are similar regarding to the application.
Larger sample sizes and higher thermomechanical loads are
responsible for to more reliable studies regarding to the application.
Acknowledgements
It is gratefully acknowledged that the study was supported
by the foundation Bayerische Forschungsstiftung (BFS) for the
joint research project Kostengnstige Kohlenstofffaserverstrkte
Keramiken AZ-710-06. Furthermore, thanks are given to, Mrs.
Ploshikhina (NMB GmbH Bayreuth, Germany) and Mr. Lauterbach
(CME, University of Bayreuth, Germany) for the support of the
microstructural studies and assistance in the design of the friction
and wear model.
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