Research article

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

  • 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.

    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

    Related Papers:

  • 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.



    加载中


    [1] Xiao JK, Xiao SX, Chen J, et al. (2020) Wear mechanism of Cu-based brake pad for high-speed train braking at speed of 380 km/h. Tribol Int 150: 106357. https://doi.org/10.1016/j.triboint.2020.106357 doi: 10.1016/j.triboint.2020.106357
    [2] Zhang P, Zhang L, Wei D, et al. (2020) A high-performance copper-based brake pad for high-speed railway trains and its surface substance evolution and wear mechanism at high temperature. Wear 444–445: 203182. https://doi.org/10.1016/j.wear.2019.203182 doi: 10.1016/j.wear.2019.203182
    [3] Mazur VL, Naidek VL, Popov YS (2021) Comparison of cast-iron and composite brake pads with cast-iron inserts for rolling stock of railways. Met Cast Ukr 29: 30–39. http://dx.doi.org/10.15407/steelcast2021.02.080 doi: 10.15407/steelcast2021.02.080
    [4] Ammar Z, Ibrahim H, Adly M, et al. (2023) Influence of natural fiber content on the frictional material of brake pads: A review. J Compos Sci 7: 72. https://doi.org/10.3390/jcs7020072 doi: 10.3390/jcs7020072
    [5] Nuryanta MI, Aryaswara LG, Korsmik R, et al. (2023) The interconnection of carbon active addition on mechanical properties of hybrid agel/glass fiber-reinforced green composite. Polymers 15: 2411. https://doi.org/10.3390/polym15112411 doi: 10.3390/polym15112411
    [6] Irawan AP, Fitriyana DF, Siregar JP, et al. (2023) Influence of varying concentrations of epoxy, rice husk, Al2O­ , and Fe2O3 on the properties of brake friction materials prepared using hand layup method. Polymers 15: 2597. https://doi.org/10.3390/polym15122597 doi: 10.3390/polym15122597
    [7] Khafidh M, Putera FP, Yotenka R, et al. (2023) A study on characteristics of brake pad composite materials by varying the composition of epoxy, rice husk, Al2O3, and Fe2O3. Automot Exp 6: 303–319. https://doi.org/10.31603/ae.9121 doi: 10.31603/ae.9121
    [8] PT Inka Multi Solusi Trading (2019) Brake shoe composite. Available from: https://imst.id/id/products/brake-shoe-composite-3/(accessed on 6 December 2023).
    [9] Maiti S, Islam MR, Uddin MA, et al. (2022) Sustainable fiber-reinforced composites: A review. Adv Sustainable Syst 6: 2200258. https://doi.org/10.1002/adsu.202200258 doi: 10.1002/adsu.202200258
    [10] Nugraha AD, Nuryanta MI, Sean L, et al. (2022) Recent progress on natural fibers mixed with CFRP and GFRP: Properties, characteristics, and failure behaviour. Polymers 14: 5138. https://doi.org/10.3390/polym14235138 doi: 10.3390/polym14235138
    [11] Sałasińska K, Cabulis P, Kirpluks M, et al. (2022) The effect of manufacture process on mechanical properties and burning behavior of epoxy-based hybrid composites. Materials 15: 301. https://doi.org/10.3390/ma15010301 doi: 10.3390/ma15010301
    [12] Nyior GB, Mgbeahuru EC (2018) Effects of processing methods on mechanical properties of alkali treated bagasse fibre reinforced epoxy composite. J Miner Mater Charact Eng 6: 345–355. https://doi.org/10.4236/jmmce.2018.63024 doi: 10.4236/jmmce.2018.63024
    [13] Irawan AP, Fitriyana DF, Tezara C, et al. (2022) Overview of the important factors influencing the performance of eco-friendly brake pads. Polymers 14: 1180. https://doi.org/10.3390/polym14061180 doi: 10.3390/polym14061180
    [14] Du DS, Tian SG, Yan J, et al. (2008) Composite material brake block special for high-speed train. China Patent No. CN101435475A.
    [15] Lv HC (2000) Composite brake shoe with great friction coefficient and its manufacture. China Patent No. CN1344640A.
    [16] Shi C (2023) Composite brake block for railway. Available from: https://green-power123.en.made-in-china.com/product/lXHnGBmAsOkx/China-Composite-Brake-Block-for-Railway.html (accessed on 29 November 2023).
    [17] Abutu J, Lawal SA, Ndaliman MB, et al. (2018) Effects of process parameters on the properties of brake pad developed from seashell as reinforcement material using grey relational analysis. Eng Sci Technol 21: 787–797. https://doi.org/10.1016/j.jestch.2018.05.014 doi: 10.1016/j.jestch.2018.05.014
    [18] Nandiyanto ABD, Hofifah SN, Girsang GCS, et al. (2021) The effects of rice husk particles size as a reinforcement component on resin-based brake pad performance: From literature review on the use of agricultural waste as a reinforcement material, chemical polymerization reaction of epoxy resin, to experiments. Automot Exp 4: 68–82. https://doi.org/10.31603/ae.4815 doi: 10.31603/ae.4815
    [19] Pinca-Bretotean C, Josan A, Sharma AK (2023) Composites based on sustainable biomass fiber for automotive brake pads. Mater Plast 60: 33–41. https://doi.org/10.37358/Mat.Plast.1964 doi: 10.37358/Mat.Plast.1964
    [20] Majeed B, Basturk S (2020) Analysis of polymeric composite materials for frictional wear resistance purposes. Polym Polym Compos 29: 127–137. https://doi.org/10.1177/0967391120903957 doi: 10.1177/0967391120903957
    [21] Olaitan AJ, Chidome AJ (2020) Development of polymer-matrix composite material using banana stem fibre and bagasse particles for production of automobile brake pad. Int J Mech Eng 5: 46–55.
    [22] Primaningtyas WE, Sakura RR, Suheni S, et al. (2019) Asbestos-free brake pad using composite polymer strengthened with rice husk powder. IOP Conf Ser Mater Sci Eng 462: 012015. https//doi: 10.1088/1757-899X/462/1/012015 doi: 10.1088/1757-899X/462/1/012015
    [23] Fuadi AM, Ataka F (2020) Pembuatan Kertas dari Limbah Jerami dan Sekam Padi dengan Metode Organosolv. Simp Nas RAPI 19: 33–38. Available from: https://publikasiilmiah.ums.ac.id/bitstream/handle/11617/12375/105.pdf?sequence = 1 & isAllowed = y.
    [24] Sharma A, Choudhary M, Agarwal P, et al. (2021) Effect of micro-sized marble dust on mechanical and thermo-mechanical properties of needle-punched nonwoven jute fiber reinforced polymer composites. Polym Composite 42: 881–898. https://doi.org/10.1002/pc.25873 doi: 10.1002/pc.25873
    [25] Fazli A, Stevanovic T, Rodrigue D (2022) Recycled HDPE/natural fiber composites modified with waste tire rubber: A comparison between injection and compression molding. Polymers 14: 3197. https://doi.org/10.3390/polym14153197 doi: 10.3390/polym14153197
    [26] Mehdikhani M, Gorbatikh L, Verpoest I, et al. (2019) Voids in fiber-reinforced polymer composites: A review on their formation, characteristics, and effects on mechanical performance. J Compos Mater 53: 1579–1669. https://doi.org/10.1177/0021998318772152 doi: 10.1177/0021998318772152
    [27] Wu MS, Centea T, Nutt SR (2018) Compression molding of reused in-process waste–effects of material and process factors. Adv Manuf Polym Compos Sci 4: 1–12. https://doi.org/10.1080/20550340.2017.1411873 doi: 10.1080/20550340.2017.1411873
    [28] Ekuase OA, Anjum N, Eze VO, et al. (2022) A review on the out-of-autoclave process for composite manufacturing. J Compos Sci 6: 172. https://doi.org/10.3390/jcs6060172 doi: 10.3390/jcs6060172
    [29] Xie J, Wang S, Cui Z, et al. (2019) Process optimization for compression molding of carbon fiber–reinforced thermosetting polymer. Materials 12: 2430. https://doi.org/10.3390/ma12152430 doi: 10.3390/ma12152430
    [30] Ochi S (2015) Flexural properties of long bamboo fiber/PLA composites. Open J Compos Mater 5: 70–78. http://dx.doi.org/10.4236/ojcm.2015.53010 doi: 10.4236/ojcm.2015.53010
    [31] Ochi S (2022) Mechanical properties of bamboo fiber bundle-reinforced bamboo powder composite materials. Eur J Wood Prod 80: 263–275. https://doi.org/10.1007/s00107-021-01757-4 doi: 10.1007/s00107-021-01757-4
    [32] Fouly A, Mohamed A, Ibrahim M, et al. (2021) Effect of low hydroxyapatite loading fraction on the mechanical and tribological characteristics of poly(methyl methacrylate) nanocomposites for dentures. Polymers 13: 857. https://doi.org/10.3390/polym13060857 doi: 10.3390/polym13060857
    [33] Suarsana K, Astika IM, Sunu PW (2019) Properties of thermal conductivity, density and hardness of aluminium matrices with reinforcement of SiCw/Al2O3 hybrid after sintering process. IOP Conf Ser Mater Sci Eng 539: 012016. https://dx.doi.org/10.1088/1757-899X/539/1/012016
    [34] Sathees Kumar S (2020) Dataset on mechanical properties of natural fiber reinforced polyester composites for engineering applications. Data Brief 28: 105054. https://doi.org/10.1016/j.dib.2019.105054 doi: 10.1016/j.dib.2019.105054
    [35] Kumar PAU, Ramalingaiah R, Suresha B, et al. (2018) Mechanical and tribological behavior of vinyl ester hybrid composites. Tribol Ind 40: 283–299. https://doi.org/10.24874/ti.2018.40.02.12 doi: 10.24874/ti.2018.40.02.12
    [36] Garg P, Gupta P, Kumar D, et al. (2016) Structural and mechanical properties of graphene reinforced aluminum matrix composites. J Mater Environ Sci 7: 1461–1473. Available from: https://www.jmaterenvironsci.com/Document/vol7/vol7_N5/161-JMES-2166-Garg.pdf.
    [37] Nawangsari P, Jamasri, Rochardjo HSB (2019) Effect of phenolic resin on density, porosity, hardness, thermal stability, and friction performance as a binder in non-asbestos organic brake pad. IOP Conf Ser Mater Sci Eng 547: 012012. https://iopscience.iop.org/article/10.1088/1757-899X/547/1/012012 doi: 10.1088/1757-899X/547/1/012012
    [38] Chen RS, Muhammad YH, Ahmad S (2021) Physical, mechanical and environmental stress cracking characteristics of epoxy/glass fiber composites: Effect of matrix/fiber modification and fiber loading. Polym Test 96: 107088. https://doi.org/10.1016/j.polymertesting.2021.107088 doi: 10.1016/j.polymertesting.2021.107088
    [39] Yawas DS, Aku SY, Amaren SG (2016) Morphology and properties of periwinkle shell asbestos-free brake pad. J King Saud Univ Eng Sci 28: 103–109. https://doi.org/10.1016/j.jksues.2013.11.002 doi: 10.1016/j.jksues.2013.11.002
    [40] Pisupati A, Ayadi A, Deléglise-Lagardère M, et al. (2019) Influence of resin curing cycle on the characterization of the tensile properties of flax fibers by impregnated fiber bundle test. Compos Part A Appl Sci Manuf 126: 105572. https://doi.org/10.1016/j.compositesa.2019.105572 doi: 10.1016/j.compositesa.2019.105572
    [41] Sumesh KR, Kanthavel K (2020) The influence of reinforcement, alkali treatment, compression pressure and temperature in fabrication of sisal/coir/epoxy composites: GRA and ANN prediction. Polym Bull 77: 4609–4629. https://doi.org/10.1007/s00289-019-02988-5 doi: 10.1007/s00289-019-02988-5
    [42] Nasution H, Suherman P, Kelvin K, et al. (2020) Mechanical properties of microcrystalline cellulose from coconut fiber reinforced waste styrofoam composite: the effect of compression molding temperature. IOP Conf Ser Mater Sci Eng 1003: 012125. https://dx.doi.org/10.1088/1757-899X/1003/1/012125
    [43] Mvondo RRN, Meukam P, Jeong J, et al. (2017) Influence of water content on the mechanical and chemical properties of tropical wood species. Results Phys 7: 2096–2103. https://doi.org/10.1016/j.rinp.2017.06.025 doi: 10.1016/j.rinp.2017.06.025
    [44] Konsta-Gdoutos MS, Danoglidis PA, Shah SP (2019) High modulus concrete: Effects of low carbon nanotube and nanofiber additions. Theor Appl Fract Mec 103: 102295. https://doi.org/10.1016/j.tafmec.2019.102295 doi: 10.1016/j.tafmec.2019.102295
    [45] Ismail AS, Jawaid M, Sultan MTH, et al, (2019) Physical and mechanical properties of woven kenaf/bamboo fiber mat reinforced epoxy hybrid composites. BioResources 14: 1390–1404. http://dx.doi.org/10.15376/biores.14.1.1390-1404
    [46] Günay M, Korkmaz ME, Ö zmen R (2020) An investigation on braking systems used in railway vehicles. Eng Sci Technol 23: 421–341. https://doi.org/10.1016/j.jestch.2020.01.009 doi: 10.1016/j.jestch.2020.01.009
    [47] Jan QMU, Habib T, Noor S, et al. (2020) Multi response optimization of injection moulding process parameters of polystyrene and polypropylene to minimize surface roughness and shrinkage's using integrated approach of S/N ratio and composite desirability function. Cogent Eng 7: 1781424. http://dx.doi.org/10.1080/23311916.2020.1781424
    [48] Rangaswamy H, Harsha HM, Chandrashekarappa MPG, et al. (2021) Experimental investigation and optimization of compression moulding parameters for MWCNT/glass/kevlar/epoxy composites on mechanical and tribological properties. J Mater Res Technol 15: 327–341. https://doi.org/10.1016/j.jmrt.2021.08.037 doi: 10.1016/j.jmrt.2021.08.037
    [49] Chen Z, Wang X, Xue B, et al. (2020) Rice husk-based hierarchical porous carbon for high performance supercapacitors: The structure-performance relationship. Carbon 161: 432–444. https://doi.org/10.1016/j.carbon.2020.01.088 doi: 10.1016/j.carbon.2020.01.088
    [50] Li MX, Lee D, Lee GH, et al. (2020) Effect of temperature on the mechanical properties and polymerization kinetics of polyamide-6 composites. Polymers 12: 1133. https://doi.org/10.3390/polym12051133 doi: 10.3390/polym12051133
    [51] Cionita T, Siregar JP, Shing WL, et al. (2022) The influence of filler loading and alkaline treatment on the mechanical properties of palm kernel cake filler reinforced epoxy composites. Polymers 14: 3063. https://doi.org/10.3390/polym14153063 doi: 10.3390/polym14153063
    [52] Jang SH, Li LY (2020) Self-sensing carbon nanotube composites exposed to glass transition temperature. Materials 13: 259. https://doi.org/10.3390%2Fma13020259
    [53] Lee LT, Tseng HY, Wu TY (2021) Crystallization behaviors of composites comprising biodegradable polyester and functional nucleation agent. Crystals 11: 1260. https://doi.org/10.3390/cryst11101260 doi: 10.3390/cryst11101260
  • Reader Comments
  • © 2023 the Author(s), licensee AIMS Press. This is an open access article distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0)
通讯作者: 陈斌, bchen63@163.com
  • 1. 

    沈阳化工大学材料科学与工程学院 沈阳 110142

  1. 本站搜索
  2. 百度学术搜索
  3. 万方数据库搜索
  4. CNKI搜索

Metrics

Article views(1088) PDF downloads(79) Cited by(2)

Article outline

Figures and Tables

Figures(7)  /  Tables(1)

/

DownLoad:  Full-Size Img  PowerPoint
Return
Return

Catalog