Evaluation of the wear resistance of aluminium-based hybrid composite brake discs under relevant city rail environments

Tan, Dong Cai; Xia, Senlin; Yob, Andrew; Yang, Kai; Yan, Shi; Givord, Michell; Liang, Daniel

doi:10.1016/j.matdes.2022.110504

Cited by 21 publications

(6 citation statements)

References 27 publications

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“…In previous studies [17,22], it was suggested that the motion between the positioning hook and positioning support might be either rolling contact or sliding contact. The wear results would differ from each other under rolling contact and sliding contact conditions.…”

Section: Experimental Methodsmentioning

confidence: 99%

“…Lakshmikanthan et al [21] investigated the influence of SiC particle size on the mechanical and tribological performance of A357 composites reinforced with dual-particle-size SiC, which indicated that hardness and wear resistance benefited from large particles. Tan et al [22] fabricated a A357/SiC aluminum matrix composite with friction-stir technology, which displayed excellent wear and friction behavior in full-scale dynamometer braking tests. Shalaby et al [23,24] improved the manufacture of A359 composites through stir and squeeze techniques, which displayed superior mechanical properties.…”

Section: Introductionmentioning

confidence: 99%

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Influence of Applied Load and Sliding Distance on Wear Performance of AlSi7Mg0.6 Aluminum Alloy

Zhang,

Zhao,

Pan

et al. 2023

Metals

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The wear performance of AlSi7Mg0.6 aluminum alloy, a casting aluminum alloy used in positioning devices for catenary systems of high-speed railways which fail frequently on lines where the speed of trains is higher than 300 m/s, is discussed in this study. It was estimated that sliding contact wear occurred and mainly contributed to the failure. To explore the competing mechanism for frictional wear failure, frictional experiments based on three groups of sliding distance (0.5 mm, 1.5 mm and 3.0 mm) and four groups of applied loads (20 N, 50 N, 100 N and 200 N) were implemented. Three-dimensional morphological observation results revealed that the wear volumes at a sliding distance of 0.5 mm were only about 1/10 of that at a sliding distance of 3.0 mm. It was also revealed that the wear volume based on a sliding distance of 3.0 mm and applied load of 20 N was still much larger than the wear volume under a sliding distance of 0.5 mm and applied load of 200 N. SEM observation of the microstructures revealed that abrasive wear was the dominant wear mechanism in dry sliding friction conditions. A simplified positioning device model was also established to study the influence of tension force on wear performance. The simulation results revealed that smaller tension force between the positioning support and positioning hook would lead to higher relative sliding distance and larger wear depth. Sliding contact friction should be avoided due to relatively large wear efficiency compared with rolling contact friction. Both experimental and simulation results suggested that proper tension force was preferred in assembling components which could ensure rolling contact friction rather than sliding contact friction.

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Section: Experimental Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Influence of Applied Load and Sliding Distance on Wear Performance of AlSi7Mg0.6 Aluminum Alloy

Zhang,

Zhao,

Pan

et al. 2023

Metals

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“…Also, it was because of the small particle size of the SiC reinforcement and a coarse matrix alloy microstructure. Tan et al [78] conducted full-scale dynamometer braking tests on HAMC brake discs made of an A357/SiC MMC top layer and an AA6082 Al alloy base joined by a friction stir process, as seen in figure 9 for rail vehicle applications. The HAMC brake disc exhibited outstanding wear and friction characteristics, offering a steady friction coefficient while withstanding high operating temperatures of up to 240 °C.…”

Section:  Tribological Propertiesmentioning

confidence: 99%

“…HAMC brake discs with cooling fins for railway application. Reproduced with permission from[78]. BY-NC-ND 4.0.…”

mentioning

confidence: 99%

Aluminium-Silicon based Metal Matrix Composites for brake rotor applications: a review

Solomon

2023

Eng. Res. Express

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In an automotive vehicle, the brake discs, also known as rotors, contribute significant weight to the engine chassis. Hence, lightweight aluminum brake discs are in the developmental stage as a popular alternative to traditional cast iron or steel brake discs. Weight reduction is desirable to improve vehicle performance and fuel efficiency. Monolithic aluminum is not a practical choice as an alternative to existing commercial brake discs because of its poor operational temperature and wear performance. Literature suggests that Aluminum Metal Matrix composite (AMC) can be an ideal choice for brake discs. AMC brake discs are more resistant to warping and cracking than cast iron discs. They also have better heat dissipation properties, which help reduce brake fade and prolong the life of the brake pads. This study examines the different types of aluminum alloys, reinforcements, and manufacturing processes for manufacturing ideal AMC brake discs. The significance of silicon as the principal alloying element to improve thermal characteristics and incorporate various reinforcements to increase the AMC's wear resistance and frictional stability for brake disc applications is outlined. This article focuses on the thermal and tribological behavior of the AMC brake discs' performance over traditional rotors. The review discusses the different equipment required to assess the tribological characteristics of brake discs to meet industrial requirements. In addition to experimental validation, this paper addresses the necessity of proper rotor design selection and numerical analysis to evaluate the thermo-mechanical behavior of the brake disc at various braking events. The article points out that aluminum metal matrix composites have great potential to replace conventional grey cast iron brake discs. Finally, this review discusses possible future research avenues for developing an AMC rotor disc.

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“…Similarly, at 15wt % of reinforcement, a drop of nearly 52% in the wear rate was reported in the HMMC in comparison to its base alloy, which was comparable to the results of the commercially available brake rotor material. Tan et al [ 34 ] prepared lightweight hybrid metal matrix composite A357/SiC/AA6082 brake discs through FSP for the city rail vehicle under the city environmental conditions. It was reported that the disc brake successfully passed the dynamometer breaking test for more than 1000 breaking test cycles.…”

Section: Introductionmentioning

confidence: 99%

Investigating the Microstructural and Mechanical Properties of Novel Ternary Reinforced AA7075 Hybrid Metal Matrix Composite

et al. 2022

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This study investigates the comparison of the microstructural and mechanical properties of a novel ternary reinforced AA7075 hybrid metal matrix composite. Four samples, including AA7075 (base alloy), AA7075-5wt %SiC (MMC), AA7075-5wt %SiC-3wt %RHA (s-HMMC), and AA7075-5wt %SiC-3wt %RHA-1wt %CES (n-HMMC) were developed using the stir casting liquid metallurgy route, followed by the heat treatment. The experimental densities corresponded with the theoretical values, confirming the successful fabrication of the samples. A minimum density of 2714 kg/m3 was recorded for the n-HMMC. In addition, the highest porosity of 3.11% was found for n-HMMC. Furthermore, an increase of 24.4% in ultimate tensile strength and 32.8% in hardness of the n-HMMC was recorded compared to the base alloy. However, its ductility and impact strength was compromised with the lower values of 5.98% and 1.5 J, respectively. This was confirmed by microstructural analysis, which reveals that n-HMMC has mixing issues and forms agglomerates in the matrix, which served as the potential sites of stress concentration leading to low impact strength and ductility. Nevertheless, the hybrid composites showed superior mechanical properties over the MMC and its base alloy.

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Evaluation of the wear resistance of aluminium-based hybrid composite brake discs under relevant city rail environments

Cited by 21 publications

References 27 publications

Influence of Applied Load and Sliding Distance on Wear Performance of AlSi7Mg0.6 Aluminum Alloy

Influence of Applied Load and Sliding Distance on Wear Performance of AlSi7Mg0.6 Aluminum Alloy

Aluminium-Silicon based Metal Matrix Composites for brake rotor applications: a review

Investigating the Microstructural and Mechanical Properties of Novel Ternary Reinforced AA7075 Hybrid Metal Matrix Composite

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