Date of Award
Master of Science
The purpose of this research was to study the friction performance characteristics of a Copper, Antimony, and sulfide free environmentally automotive friction material using different allotropes of graphite as a replacement. Model brake friction materials were created and tested on a full scale brake dynamometer using the Society of Automotive Engineers J2430 test and Brake Effectiveness Evaluation Procedure. The dynamometer testing revealed the graphite replacement to have higher average effectiveness values when compared to the baseline friction material currently in production. The model samples generally had higher wear rates but some were comparable to the baseline and would be acceptable in real world applications. Some of the model samples displayed stable characteristics under varying load and linear braking velocity conditions, ultimately passing the criteria required. The model samples (RD18670A/B/C/D/E/F/G) displayed average effectiveness values of 0.425, 0.435, 0.4125, 0.425, 0.475, failed test, and 0.35 respectively, which is on average a substantial gain over the baseline effectiveness value average of 0.3125. Sample RD18670F proved to be the most promising replacement for the baseline 1999 Ford Crown Victoria friction lining. This is due to a higher average effectiveness value of 0.5, during both the high speed and low speed testing, than the baseline friction lining material of 0.325. Also, RD18670F displayed comparable wear rates to the baseline test, with 0.384mm lost inboard and 0.650 lost outboard, representing a difference of only 0.074mm and 0.2mm respectively from the baseline.
This thesis is Open Access and may be downloaded by anyone.