Thermal Cracking and Friction Performance of Two Kinds of Compacted Graphite Iron Brake Discs under Intensive Braking Conditions
Abstract
:1. Introduction
2. Materials and Methods
2.1. Materials
2.2. Microstructure Characterization
2.3. Mechanical and Physical Properties
2.4. Inertia Friction Tests
3. Results and Discussion
3.1. Microstructure and Properties
3.2. Peak Temperature and Input Pressure
3.3. Friction Coefficient and Its Stability
3.4. Thermal Cracks and Wear
4. Conclusions
- Due to the higher thermal conductivity of ferrite compared to pearlite, the increased ferrite proportion led to a decrease in the thermal stress of the CGI discs. The peak temperature of the HC1 disc with a 49.4% ferrite proportion ranged from 250 °C to 290 °C, and the HC2 disc with an 80.1% ferrite proportion had a peak temperature range of 210 °C to 250 °C.
- The higher content of soft ferrite in the HC2 disc led to furrows with a larger height on the worn surface, which increased the contact area between the disc and pads. As a result, the HC2 disc–pads pair provided a higher friction coefficient and improved the stability in the friction coefficient despite having a lower peak temperature and smaller thermal expansion. Moreover, the higher friction coefficient in HC2 led to a decrease in the input pressure loads from pads under fixed deceleration.
- The increase in the ferrite proportion also reduced the oxidation of the matrix in the HC2 brake disc due to lower disc temperatures. The decreased oxidation of the matrix, along with lower thermal stresses and reduced pressure loads, resulted in fewer thermal cracks in the HC2 brake disc.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Disc | C | Si | Mn | P | S | Mo | Cu | Sn | CE |
---|---|---|---|---|---|---|---|---|---|
HC1 | 3.63 | 2.39 | 0.45 | 0.044 | 0.027 | 0.35 | 0.60 | 0.044 | 4.44 |
HC2 | 3.59 | 2.42 | 0.45 | 0.043 | 0.022 | 0.45 | 0.59 | 0.025 | 4.41 |
Item | Details |
---|---|
Test parameters | Test type: front axle brake disc Test mass: 812.35 kg Tire rolling radius: 316 mm Rotary inertia: 81.1 kg·m2 Piston diameter: 60 mm Piston number: 1 Effective radius: 134.75 mm |
Bedding in procedure | A total of 100 brake applications were used. In each braking application, the disc was braked from 60 km·h−1 to 30 km·h−1. The deceleration alternated between 1 m·s−2 and 2 m·s−2. The disc’s initial temperature started at room temperature. After 30 applications, the initial temperature of the disc was set to not exceed 300 °C, achieved by applying cooling air at 28 °C. The speed of the cooling air was maintained at 19.3 km·h−1. |
High-deceleration test procedure | A total of 70 braking applications were applied. In each application, the disc was braked from 180 km·h−1 to 10 km·h−1 with a deceleration of 10 m·s−2. Before each application, the temperature of the disc was cooled to 100 °C by cooling air. The temperature and speed of the cooling air were 28 °C and 49.9 km·h−1, respectively. |
Item | HC1 | HC2 |
---|---|---|
Graphite percentage (%) | 12.4 ± 0.3 | 12.0 ± 0.5 |
Ferrite proportion (%) | 49.4 ± 3.6 | 80.1 ± 4.8 |
Vermicularity (%) | 83.1 ± 4.2 | 84.4 ± 3.7 |
Tensile strength (MPa) | 442 ± 11 | 348 ± 14 |
Brinell hardness (HBW) | 228 ± 9 | 174 ± 6 |
Microhardness of ferrite (HV) | 192.9 ± 14.3 | 174.4 ± 16.1 |
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Xu, Z.; Wang, G.; Li, Y. Thermal Cracking and Friction Performance of Two Kinds of Compacted Graphite Iron Brake Discs under Intensive Braking Conditions. Metals 2024, 14, 332. https://doi.org/10.3390/met14030332
Xu Z, Wang G, Li Y. Thermal Cracking and Friction Performance of Two Kinds of Compacted Graphite Iron Brake Discs under Intensive Braking Conditions. Metals. 2024; 14(3):332. https://doi.org/10.3390/met14030332
Chicago/Turabian StyleXu, Zhuo, Guiquan Wang, and Yanxiang Li. 2024. "Thermal Cracking and Friction Performance of Two Kinds of Compacted Graphite Iron Brake Discs under Intensive Braking Conditions" Metals 14, no. 3: 332. https://doi.org/10.3390/met14030332