Effect of compression molding temperature on the characterization of asbestos-free composite friction materials for railway applications

Rahmad Doni Widodo; Rusiyanto; Wahyudi; Melisa Kartika Sari; Deni Fajar Fitriyana; Januar Parlaungan Siregar; Tezara Cionita; Natalino Fonseca Da Silva Guterres; Mateus De Sousa Da Silva; Jamiluddin Jaafar; Rahmad Doni Widodo; Rusiyanto; Wahyudi; Melisa Kartika Sari; Deni Fajar Fitriyana; Januar Parlaungan Siregar; Tezara Cionita; Natalino Fonseca Da Silva Guterres; Mateus De Sousa Da Silva; Jamiluddin Jaafar

doi:10.3934/matersci.2023059

AIMS Materials Science

2023, Volume 10, Issue 6: 1105-1120. doi: 10.3934/matersci.2023059

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Research article

Effect of compression molding temperature on the characterization of asbestos-free composite friction materials for railway applications

1.
Department of Mechanical Engineering, Universitas Negeri Semarang, Semarang 50229, Indonesia
2.
Faculty of Mechanical & Automotive Engineering Technology, Universiti Malaysia Pahang Al-Sultan Abdullah, Pekan 26600, Pahang, Malaysia
3.
Faculty of Engineering and Quantity Surveying, INTI International University, Nilai 71800, Negeri Sembilan, Malaysia
4.
Department of Mechanical Engineering, Dili Institute of Technology, Aimeti Laran Street, Dili-Timor Leste
5.
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, Parit Raja, Batu Pahat 86400, Johor, Malaysia

Received: 14 November 2023 Revised: 29 November 2023 Accepted: 30 November 2023 Published: 08 December 2023

Brake pads significantly affect the braking performance of railways under both normal and emergency operating conditions. In previous studies, brake pads were made using the hand lay-up method and produced the best properties on specimens with epoxy, rice husk, Al₂O₃ and Fe₂O₃ compositions of 50%, 20%, 15% and 15%. However, the resulting density does not meet the density standard set by PT Industri Kereta Api Indonesia (PT INKA), which is 1.7–2.4 g/cm³. To date, there has been limited research into the utilization of the compression hot molding method for the production of asbestos-free composite friction materials composed of epoxy, rice husk, Al₂O₃ and Fe₂O₃ for railway applications. In this study, we aimed to determine the effect of compression molding temperature on the characterization of composite brake pads for railway applications. The brake pad specimens were made of epoxy resin, rice husk, Al₂O₃ and Fe₂O₃ with a composition of 50%, 20%, 15% and 15%, respectively. The manufacture of composites in this study used the compression molding method with a pressure of 20 MPa for 15 min holding time. The mold temperature used were 80, 100, 120 ℃. Density, hardness, tensile, wear, thermal gravimetric analysis (TGA) and differential scanning calorimetry (DSC) tests were performed to evaluate the properties of the specimens obtained. The results demonstrated that an increase in molding temperature improved the characterization of the brake pads, with the best results achieved at a molding temperature of 120 ℃ (SP-3 specimen). SP-3 specimens had the best density, hardness, tensile properties and thermal properties compared to other specimens.
- brake pads,
- railways,
- composites,
- compression molding,
- friction materials
Citation: Rahmad Doni Widodo, Rusiyanto, Wahyudi, Melisa Kartika Sari, Deni Fajar Fitriyana, Januar Parlaungan Siregar, Tezara Cionita, Natalino Fonseca Da Silva Guterres, Mateus De Sousa Da Silva, Jamiluddin Jaafar. Effect of compression molding temperature on the characterization of asbestos-free composite friction materials for railway applications[J]. AIMS Materials Science, 2023, 10(6): 1105-1120. doi: 10.3934/matersci.2023059

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Abstract

Brake pads significantly affect the braking performance of railways under both normal and emergency operating conditions. In previous studies, brake pads were made using the hand lay-up method and produced the best properties on specimens with epoxy, rice husk, Al₂O₃ and Fe₂O₃ compositions of 50%, 20%, 15% and 15%. However, the resulting density does not meet the density standard set by PT Industri Kereta Api Indonesia (PT INKA), which is 1.7–2.4 g/cm³. To date, there has been limited research into the utilization of the compression hot molding method for the production of asbestos-free composite friction materials composed of epoxy, rice husk, Al₂O₃ and Fe₂O₃ for railway applications. In this study, we aimed to determine the effect of compression molding temperature on the characterization of composite brake pads for railway applications. The brake pad specimens were made of epoxy resin, rice husk, Al₂O₃ and Fe₂O₃ with a composition of 50%, 20%, 15% and 15%, respectively. The manufacture of composites in this study used the compression molding method with a pressure of 20 MPa for 15 min holding time. The mold temperature used were 80, 100, 120 ℃. Density, hardness, tensile, wear, thermal gravimetric analysis (TGA) and differential scanning calorimetry (DSC) tests were performed to evaluate the properties of the specimens obtained. The results demonstrated that an increase in molding temperature improved the characterization of the brake pads, with the best results achieved at a molding temperature of 120 ℃ (SP-3 specimen). SP-3 specimens had the best density, hardness, tensile properties and thermal properties compared to other specimens.

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