Littérature scientifique sur le sujet « Particulate matte, brake emissions, friction materials »

Brake-wear particle emissions are the result of the components of a friction brake being in tribological contact, and they are classified as non-exhaust emissions. Since most of the emitted particles belong to the size classes of particulate matter (≤10 μm) and differ significantly in terms of their physico-chemical properties from automotive exhaust emissions, this source is of particular relevance to human health and, therefore, the focus of scientific studies. Previous studies have shown that coated brake discs offer significant wear and emission reduction potential. Nevertheless, no studies are available that describe the specific particle formation process, the contact conditions, the structure of the friction layer and the differences compared to conventional grey cast iron discs. The aim of this study is to describe those differences. For this purpose, the tribological behaviour, the structure of the friction layer and the associated particle dynamics within the friction contact between a laser cladding coated disc and a conventional grey cast iron disc are compared. The required investigations are carried out both ex situ (stationary) and in situ (dynamic). Parallel to the tribological investigations, the particle emission behaviour is determined on an inertia dynamometer using a constant volume sampling system (CVS) and equipment for particle number and particle size distribution measurement. The results show that, for two different brake pads, the laser cladding brake disc has lower wear and less particulate emissions than the grey cast iron brake disc. The wear behaviour of the coating varies significantly for the two brake pads. By contrast, the grey cast iron brake disc shows a significantly lower influence.

Reduction of non-exhaust airborne particulate matter (PM), leading to adverse effects in respiratory system, is an urgent task. In this work, we evaluated the impact of raw materials in friction materials on PM emission due to brake wear for passenger vehicle. Time- and temperature-dependent measurements using dynamometer were made for low-steel friction materials with varied abrasives and lubricant(graphite). The brake emission factor (BEF) for graphite of varied sizes ranged from 6.48 to 7.23 mg/km/vehicle. The number concentration indicates that smaller graphite (10 μm) produces more nano-sized particles than larger size (700 μm) by >50%. Depending on abrasives, BEF was found to be varied as large as by three-times, ranging from 4.37 to 14.41 mg/km/vehicle. As hardness of abrasive increases (SiC > Al2O3 > ZrSiO4), higher BEF was obtained, suggesting that abrasive wear directly contributes to emissions, evidenced by surface topology. Temperature-dependent data imply that particle emission for SiC abrasive is initiated at lower speed in WLTC cycle, where disc temperature (Tdisc) is ~100 °C, than that for ZrSiO4 (Tdisc >120 °C). Analysis of wear debris suggests that larger micron-sized particles include fragmented Fe lumps from disc, whereas smaller particles are, in part, formed by combination of oxidation and aggregation of nano-sized particles into small lumps.

An important contributor to non-exhaust emissions in urban areas is airborne particulate matter originating from brake systems. A well-established way to test such systems in industry is to use inertia dynamometer benches; although they are quite expensive to run. Pin-on-disc tribometers, on the other hand, are relatively cheap to run, but simplify the real system. The literature indicates promising correlations between these two test stands with regard to measured airborne number distribution. Recent studies also show a strong dependency between the airborne number concentration and the disc temperature. However, a direct comparison that also takes into account temperature effects is missing. The aim of this paper is, therefore, to investigate how the transition temperature is affected by the different test scales, under dragging conditions, and the effects on total concentration and size distribution. New and used low-steel pins/pads were tested against cast iron discs/rotors on both the aforementioned test stands, appositely designed for particulate emission studies. A constant normal load and constant rotational velocity were imposed in both test stands. Results show that a transition temperature can always be identified. However, it is influenced by the test scale and the frictional pair status. Nevertheless, emissions are assessed similarly when an equivalent frictional pair status is analysed (e.g. run-in). Further investigations for fully run-in samples on the pin-on-disc should be performed in order to finally assess the possibility of using the tribometers for the initial assessment of different friction materials.

An automotive friction brake pad is a complex system consisting of several components with unique and balanced properties related to operation conditions. There are efforts to develop brake pads with longer lifetime and better friction performance and wear properties. Those properties are related to composition of the pads, and therefore, new materials are being evolved. Tuning the friction and wear properties can be achieved with the selection of a functional filler and optimizing its amount in a formulation of friction brake pad. Laboratory-developed and laboratory-prepared nanocomposite material kaolin/TiO2 (KATI) has been introduced to formulation of the commercially available automotive low-steel brake pad. Kaolin was utilized as a matrix for anchoring TiO2 nanoparticles. New unused pads and pads after AK master, a standard dynamometer testing procedure of friction performance, were investigated using light and scanning electron microscopy providing information on the structure and its changes after the friction processes. Moreover, MTK wear test was used to compare wear rate of the newly developed pad with the reference low-steel pad. Improved durability of the brake pad formulation has been observed together with sufficient friction performance. Microscopic analysis shown homogenous distribution of the KATI nanocomposite in the friction layer. From the obtained results, it can be assumed that the new formulation is promising regarding to the life cycle of the pads and reduction of wear rate and thus potential production of wear particulate emissions.

AbstractThe need to reduce non-exhaust particulate matter emissions is of paramount importance as they pose repercussions on human lives and the environment. In this study, a novel way to limit emissions is proposed based on the minimization of the vibration of the mating bodies. Two model friction material formulations were tested in the form of pins and paired with a pearlitic grey cast iron disc counterface in a laboratory pin on disc apparatus. To reduce the vibrations, a damping tape was wrapped around the pins. With the damping of vibration, a significant drop in the emissions was recorded, and this was correlated with the friction layer establishment during sliding, which observed low disruption. It is believed that the use of this method for reducing emissions can accompany the optimization phase of the brake squeal noise of friction materials, thereby, providing new design perspectives.

Automotive brake systems are source of particulate matter (PM) emissions, particularly in the urban areas. Several human ill-health are related with this kind of pollution. Along tire wear, road wear and dust from resuspension, the brake wear comprises the most relevant non-exhaust source of road traffic related emissions. Aiming at studying the PM brake emissions, this thesis is composed of an introductory part containing the main concepts and the state of art of the main subjects; and the experimental part, which comprehends three investigations. Chapters 2, 3, 4 and 5 are dedicated to the introduction part. Chapter 2 provides a brief description of the friction and wear, as well as the fundamental principles of braking by contact. Chapter 3 discuss the disc braking system, with particular attention to the pad friction materials. Chapter 4 is dedicated to friction layer: the layer usually developing at the disc/pad interface, affecting the performances of the tribological system. Finally, Chapter 5 provides an extensive discussion of the issues related to the particulate matter originated from disc brake systems. The experimental part is presented in the Chapters 6, 7, 8 and 9. Chapter 6 describes the methodology applied in all the investigations. Chapter 7 investigates the PM emissions behavior and its interaction with the friction and wear, aiming to identify the mechanism of generation the PM emissions. A copper-containing and a copper-free commercial friction materials were used, with particular emphasis on the effect of the scorching treatment. The Chapter 8 is dedicated at investigating the tribological behavior and the corresponding PM emissions in two Cu-free commercial friction materials, aiming to a better understanding the effect of abrasive ingredients on the emissions generation. Finally, the Chapter 9 investigated the addition of natural ingredient rice husk in a new eco-friendly Cu-free brake friction material composition, focusing the attention on the tribological and emissions behavior. All tests were carried out using a pin-on-disc tribometer equipped with an enclosure, especially designed for investigating the tribological properties, as well as the airborne particles generated by contact. Low-metallic friction materials, both commercial and laboratory-produced, were tested against cast iron discs. The tests parameters used correspond to mild sliding conditions resembling those faced in real braking. Such conditions are characteristic of driving in urban areas, where the expose to traffic PM is concentrated. A specific methodology of analysis was developed, based on SEM/EDXS techniques. Using this methodology, comparative investigations between the elemental composition of the virgin friction materials, the worn surfaces of the friction materials and the airborne particles collected during the tribological tests were carried out. The results point out the triboxidative wear as the main mechanism of the PM brake emissions generation. Moreover, particles produced by abrasive wear can be also directly emitted to the environment.

Brake wear debris and its contents have been matters of concern due to their impacts on the human body and the environment, which has led to many studies being done in the brake industry. In North America, copper is a prime example of brake wear debris impacting the environment when it’s exhausted to the atmosphere. The regulation of copper content in brake pads for new cars has been enacted and has led to the development of copper free friction materials which are used in the market today In Europe, micro particles such as PM2.5 and PM10 contained in the brake wear debris, which are also called BPE (brake particle emissions), are considered to affect human health and air pollution. As regulatory activities have accelerated, so has the work towards establishing measuring methods of BPE. As a brake supplier, fundamental research is necessary for understanding characteristics of BPE and reducing the amount of BPE for each type of friction material. As the first step of the research, BPE characteristics were investigated for various friction materials, such as Low Steel, Non Asbestos Organic, and Cu-Free Non Asbestos Organic. In addition, a hard coated rotor was also prototyped and investigated. In this study, a brake corner for a compact passenger car was used for testing. Particulate mass (PM2.5 and PM10) were obtained by a measurement system in accordance with JASO C470 (established in 2020). Also, the CPC (condensation particle counter) device was added to this system in order to measure the particulate number (PN) which was proposed in the WP29/GRPE/PMP/TF2 document. As a result, there were significant differences in the amount of BPE among the friction materials tested. The results also show good correlation between the amount of BPE and wear mass of the pad and rotor. In addition, it is suggested that PM2.5 account for 9-18% of wear mass, PM10 for 31-43% in this test condition.

"Significant efforts are currently on going to decrease the non-exhaust emissions from transport sector. As far as the brake system is concerned, these efforts are mostly associated with the research of new friction couples and technological solutions capable to reduce the generation of fine particulate at the brake pad – disc interface. An additional strategy to reduce the environmental impact of brake emissions can arise from: a) increasing the emission particle dimensions; and b) tailoring their chemical composition. Consequently, prior to perform any environmental and toxicological assessment, it is fundamental to characterize the emissions in terms of composition, dimensions, and morphology. At this regard, the work proposes an effective analytical method for the ex-situ characterization of fine particulates (PM10) emitted in air and coarser emissions falling directly to the ground, as obtained by the coupling of Low Steel and NAO friction materials and a reference grey cast iron disc. The Particle Size Distribution (PSD) and chemical composition of the emissions are investigated by the means of a multi-technique protocol based on Scanning Electron Microscopy (SEM), Laser Diffraction (LD), Energy Dispersive Spectroscopy (EDS) and X-Ray Diffraction (XRD). Results unveil the complex interplay existing between each typology of investigated friction material and the morphology/chemical composition of the corresponding emitted particulates. "