Potential Optimization of Industrial Waste as an Alternative Material for Composite Filler in Brake Pad Manufacturing – A Review
Abstract
This study investigates the sustainable utilization of fly ash, palm slag and Cement By-Pass Dust (CBPD) waste as alternative materials for environmentally friendly brake pad development. These waste materials, with compositions similar to Asbestos, historically used in brake pad composites, present an eco-conscious solution. Integrating industrial waste in brake pad production offers substantial environmental benefits, technological progress, and commercial advantages. The compaction value and particle size distribution significantly impact brake pad mechanical properties. Adjusting these factors is crucial for meeting desired mechanical property requirements. A large particle size distribution enhances material density and hardness poses challenges in maintaining performance stability at high temperatures despite good recovery values. This paper highlights the potential of waste materials for sustainable brake pad development and underscores the need for careful optimization for high-temperature stability.
##Keywords:##
Brake pad, Waste management, Industrial waste, fly ash, Cement waste, Palm slag, Non-asbestos composite.
Published
Mar 30, 2024
How to Cite
SATIVA, Oriza; NAWANGSARI, Putri.
Potential Optimization of Industrial Waste as an Alternative Material for Composite Filler in Brake Pad Manufacturing – A Review.
Journal of Ocean, Mechanical and Aerospace -science and engineering-, [S.l.], v. 68, n. 1, p. 40-52, mar. 2024.
ISSN 2527-6085.
Available at: <https://isomase.org/Journals/index.php/jomase/article/view/356>. Date accessed: 19 aug. 2024.
doi: http://dx.doi.org/10.36842/jomase.v68i1.356.
References
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[28] Singh, T. (2021). Utilization of cement bypass dust in the development of sustainable automotive brake friction composite materials. Arabian Journal of Chemistry, 14(9), 103324.
[29] Saleh, H.M., El-Saied, F.A., Salaheldin, T.A. & Hezo, A.A. (2018). Macro-and nanomaterials for improvement of mechanical and physical properties of cement kiln dust-based composite materials. Journal of Cleaner Production, 204, 532-541.
[30] Singh, T., Tiwari, A., Patnaik, A., Chauhan, R. & Ali, S. (2017). Influence of wollastonite shape and amount on tribo-performance of non-asbestos organic brake friction composites. Wear, 386, 157-164.
[31] Singh, T., Patnaik, A. & Chauhan, R. (2016). Optimized selection of cement kiln dust filled brake pad formulation for best tribo-performance properties using Grey Relation Analysis approach. Mater Design, 89, 1335-1342.
[32] Singh, T. (2023). Comparative performance of barium sulphate and cement by-pass dust on tribological properties of automotive brake friction composites. Alexandria Engineering Journal, 72, 339-349.
[33] Kawabe, K., Kawai, T., Komoto, T. & Kuroda, S.I. (2011). Mechanical and Morphological Studies on compressive properties of brake materials. Sen'i Gakkaishi, 67(7), 153-162.
[34] Guo, L., Li, H., Li, K., Zhang, D. & Wang, C. (2009). Effect of the fabrication process on the properties of pitch based carbon-carbon composites. The 17th International Conference on Composites (ICCM 17, Ediburgh, UK.
[35] Kim, Y.C., Cho, M.H., Kim, S.J. & Jang, H. (2008). The effect of phenolic resin, potassium titanate, and CNSL on the tribological properties of brake friction materials. Wear, 264(3-4), 204-210.
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[37] Manoharan, S., Vijay, R., Lenin Singaravelu, D. & Kchaou, M. (2019). Experimental investigation on the tribo-thermal properties of brake friction materials containing various forms of graphite: a comparative study. Arabian Journal for Science and Engineering, 44, 1459-1473.
[38] Kumar, M. & Bijwe, J. (2010). Studies on reduced scale tribometer to investigate the effects of metal additives on friction coefficient–temperature sensitivity in brake materials. Wear, 269(11-12), 838-846.
[39] Onyeneke, F.N., Anaele, J.U. & Ugwuegbu, C.C. (2014). Production of motor vehicle brake pad using local materials (perriwinkle and coconut shell). The International Journal Of Engineering And Science (IJES), 9, 17-24.
[40] Bijwe, J., Majumdar, N. & Satapathy, B.K. (2005). Influence of modified phenolic resins on the fade and recovery behavior of friction materials. Wear, 259(7-12), 1068-1078.
[41] Tiwari, A., Jaggi, H.S., Kachhap, R.K., Satapathy, B.K., Maiti, S.N. & Tomar, B.S. (2014). Comparative performance assessment of cenosphere and barium sulphate based friction composites. Wear, 309(1-2), 259-268.
[42] Sun, W., Zhou, W., Liu, J., Fu, X., Chen, G. & Yao, S. (2018). The size effect of SiO 2 particles on friction mechanisms of a composite friction material. Tribology Letters, 66, 1-10.
[2] Kchaou, M., Sellami, A., Fajoui, J., Kus, R., Elleuch, R. & Jacquemin, F. (2019). Tribological performance characterization of brake friction materials: What test? What coefficient of friction?. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 233(1), 214-226.
[3] Sun, Y., Wang, Y., Zhu, R., Geng, R., Zhang, J., Fan, D. & Wang, H. (2018, December). Study on the control strategy of regenerative braking for the hybrid electric vehicle under typical braking condition. In IOP Conference Series: Materials Science and Engineering, 452(3), 032092). IOP Publishing.
[4] Liu, Y., Wang, L., Liu, D., Ma, Y., Tian, Y., Tong, J., et al. (2019). Evaluation of wear resistance of corn stalk fiber reinforced brake friction materials prepared by wet granulation. Wear, 432, 102918.
[5] Singh, T., Patnaik, A., Chauhan, R. & Rishiraj, A. (2017). Assessment of braking performance of lapinus–wollastonite fibre reinforced friction composite materials. Journal of King Saud University-Engineering Sciences, 29(2), 183-190.
[6] Nicholson, G. (1995). Facts about Friction. P&W Price Enterprises, Croydon, PA.
[7] Sugözü, B. & Da?han, B. (2016). Effect of BaSO4 on tribological properties of brake friction materials. International Journal Innovative Research in Science, Engineering, and Technology, 5(12), 30-35.
[8] Handa, Y. & Kato, T. (1996). Effects of Cu powder, BaSO4 and cashew dust on the wear and friction characteristics of automotive brake pads. Tribology Transactions, 39(2), 346-353.
[9] Singaravelu, D.L., Vijay, R., Manoharan, S. & Kchaou, M. (2019). Development and performance evaluation of eco-friendly crab shell powder based brake pads for automotive applications. International Journal of Automotive and Mechanical Engineering, 16(2), 6502-6523.
[10] Nawangsari, P. & Rochardjo, H.S.B. (2019). Effect of phenolic resin on density, porosity, hardness, thermal stability, and friction performance as a binder in non-asbestos organic brake pad. In IOP Conference Series: Materials Science and Engineering, 547(1), 012012. IOP Publishing.
[11] Ubani, A.C. & Adejare, O.G. (2022). Development of a vehicle brake pad using composites of palm kernel fiber and groundnut shells as filler material. Quest Journals Journal of Research in Mechanical Engineering, 8(9), 1-10.
[12] Chan, D. & Stachowiak, G.W. (2004). Review of automotive brake friction materials. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 218(9), 953-966.
[13] Ruzaidi-Ghazali, C.M.., Kamarudin, H., Jamaludin, S. B., Al Bakri, A.M., & Liyana, J. (2013). Mechanical properties and morphology of palm slag, calcium carbonate and dolomite filler in brake pad composites. Applied Mechanics and Materials, 313, 174-178.
[14] Ruzaidi-Ghazali, C.M.R., Kamarudin, H., Jamaludin, S. B. & Abdullah, M.M.A.B. (2011). Comparative study on thermal, compressive, and wear properties of palm slag brake pad composite with other fillers. Advanced Materials Research, 328, 1636-1641.
[15] Ruzaidi-Ghazali, C.M. , Kamarudin, H., Shamsul, J.B., Abdullah, M.M.A.B. & Rafiza, A.R. (2012). Mechanical properties and wear behavior of brake pads produced from palm slag. Advanced materials research, 341, 26-30.
[16] Chand, N,, Hashmi, S.A.R., Lomash, S. & Naik, A. (2004). Development of asbestos free brake pad. Journal MC (Journal of Institution of Engineers (India): Mechanical Engineering Division), 85, 13-16.
[17] Khoni, N.A.A., Ghazali, C.M.R. & Abdullah, M.M.A.B. (2018). Friction and braking application of unhazardous palm slag brake pad composite. In IOP Conference Series: Materials Science and Engineering, 343(1), 012014. IOP Publishing.
[18] Ruzaidi, C.M., Khoni, N.A.A., Suriani, M. J., Abdullah, W.R.W. & Abdullah, M.M.A. (2020). Effect of waste tire dust on the hardness and wear rate of palm slag friction composites. In IOP Conference Series: Materials Science and Engineering (864(1), 012004). IOP Publishing.
[19] Basu, M., Pande, M., Bhadoria, P.B.S. & Mahapatra, S.C. (2009). Potential fly-ash utilization in agriculture: a global review. Progress in Natural Science, 19(10), 1173-1186.
[20] Kishor, P., Ghosh, A.K. & Kumar, D. (2010). Use of fly ash in agriculture: A way to improve soil fertility and its productivity. Asian Journal of Agricultural Research, 4(1), 1-14.
[21] Acosta, D. (2009). Pemanfaatan Fly Ash (Abu Terbang) Dari Pembakaran Batubara Pada PLTU Suralaya Sebagai Bahan Baku Pembuatan Refraktori Cor. Jurnal
Teknik Kimia, 3, 67-75.
[22] Dadkar, N., Tomar, B. S., & Satapathy, B. K. (2009). Evaluation of flyash-filled and aramid fibre reinforced hybrid polymer matrix composites (PMC) for friction braking applications. Materials & Design, 30(10), 4369-4376.
[23] Öztürk, B. & Mutlu, T. (2016). Effects of zinc borate and fly ash on the mechanical and tribological characteristics of brake friction materials. Tribology Transactions, 59(4), 622-631.
[24] Mohanty, S. & Chugh, Y.P. (2007). Development of fly ash-based automotive brake lining. Tribology International, 40(7), 1217-1224.
[25] Czapik, P., Zapa?a-S?aweta, J., Owsiak, Z. & St?pie?, P. (2020). Hydration of cement by-pass dust. Construction and Building Materials, 231, 117139.
[26] Bai, X., Liu, W., Wu, B., Liu, S., Liu, X., Hao, Y., et al. (2023). Emission characteristics and inventory of volatile organic compounds from the Chinese cement industry based on field measurements. Environmental Pollution, 316, 120600.
[27] Abdel-Gawwad, H.A., Rashad, A.M., Mohammed, M.S. & Tawfik, T.A. (2021). The potential application of cement kiln dust-red clay brick waste-silica fume composites as unfired building bricks with outstanding properties and high ability to CO2-capture. Journal of Building Engineering, 42, 102479.
[28] Singh, T. (2021). Utilization of cement bypass dust in the development of sustainable automotive brake friction composite materials. Arabian Journal of Chemistry, 14(9), 103324.
[29] Saleh, H.M., El-Saied, F.A., Salaheldin, T.A. & Hezo, A.A. (2018). Macro-and nanomaterials for improvement of mechanical and physical properties of cement kiln dust-based composite materials. Journal of Cleaner Production, 204, 532-541.
[30] Singh, T., Tiwari, A., Patnaik, A., Chauhan, R. & Ali, S. (2017). Influence of wollastonite shape and amount on tribo-performance of non-asbestos organic brake friction composites. Wear, 386, 157-164.
[31] Singh, T., Patnaik, A. & Chauhan, R. (2016). Optimized selection of cement kiln dust filled brake pad formulation for best tribo-performance properties using Grey Relation Analysis approach. Mater Design, 89, 1335-1342.
[32] Singh, T. (2023). Comparative performance of barium sulphate and cement by-pass dust on tribological properties of automotive brake friction composites. Alexandria Engineering Journal, 72, 339-349.
[33] Kawabe, K., Kawai, T., Komoto, T. & Kuroda, S.I. (2011). Mechanical and Morphological Studies on compressive properties of brake materials. Sen'i Gakkaishi, 67(7), 153-162.
[34] Guo, L., Li, H., Li, K., Zhang, D. & Wang, C. (2009). Effect of the fabrication process on the properties of pitch based carbon-carbon composites. The 17th International Conference on Composites (ICCM 17, Ediburgh, UK.
[35] Kim, Y.C., Cho, M.H., Kim, S.J. & Jang, H. (2008). The effect of phenolic resin, potassium titanate, and CNSL on the tribological properties of brake friction materials. Wear, 264(3-4), 204-210.
[36] Rothon, R.N. (2003). Particulate-filled polymer composites. Smithers Rapra Publishing.
[37] Manoharan, S., Vijay, R., Lenin Singaravelu, D. & Kchaou, M. (2019). Experimental investigation on the tribo-thermal properties of brake friction materials containing various forms of graphite: a comparative study. Arabian Journal for Science and Engineering, 44, 1459-1473.
[38] Kumar, M. & Bijwe, J. (2010). Studies on reduced scale tribometer to investigate the effects of metal additives on friction coefficient–temperature sensitivity in brake materials. Wear, 269(11-12), 838-846.
[39] Onyeneke, F.N., Anaele, J.U. & Ugwuegbu, C.C. (2014). Production of motor vehicle brake pad using local materials (perriwinkle and coconut shell). The International Journal Of Engineering And Science (IJES), 9, 17-24.
[40] Bijwe, J., Majumdar, N. & Satapathy, B.K. (2005). Influence of modified phenolic resins on the fade and recovery behavior of friction materials. Wear, 259(7-12), 1068-1078.
[41] Tiwari, A., Jaggi, H.S., Kachhap, R.K., Satapathy, B.K., Maiti, S.N. & Tomar, B.S. (2014). Comparative performance assessment of cenosphere and barium sulphate based friction composites. Wear, 309(1-2), 259-268.
[42] Sun, W., Zhou, W., Liu, J., Fu, X., Chen, G. & Yao, S. (2018). The size effect of SiO 2 particles on friction mechanisms of a composite friction material. Tribology Letters, 66, 1-10.
