Synergistic performance of expanded graphite—mica amalgamation based non-asbestos copper-free brake friction composites

Abstract Recent advancements in brake pad applications emphasise various friction compositions that exclude toxic components such as asbestos, copper etc, in order to provide superior performance without hurting the environment, human life and aquarium species. In this work, brake friction materials were fabricated by the conventional manufacturing process as standard brake pads using expanded graphite with the synergetic effect of thermal resistant material mica flakes. Six standard brake pads were produced based on varying the expanded graphite by 16, 14, 12, 8, 6 & 4 weight percentage, which is compensated using the Mica flakes by 4, 6, 8, 12, 14 & 16 weight percentage, fixing the composition of other ingredients and designated as BM01, BM02, BM03, BM04, BM05 and BM06. Physical, chemical and mechanical, characterisations of the formed friction materials were carried out in accordance with IS 2742 and ISO 6312. A full-scale inertia brake dynamometer was used to determine the fade, recovery characterisations with the pressure and speed sensitivity as of JASO-C-406. From the experimental observations, BM03 friction composites reveal excellent low fade and high recovery characteristics because of the integrated effect of expanded graphite (superior lubricity) & mica (good thermal stability). Worn surface analysis was studied with the help of a scanning electron microscope. The inclusion of expanded graphite-mica as a hybrid ‘lubricant-filler’ combination in composite materials for friction braking application results in performance synergism.