Development of gray cast iron alloy modified by Niobium for brake disc production

ABSTRACT

Disc brake systems are used on a large scale in the global automotive industry, due to their efficiency, system simplicity and easy maintenance. In this work, niobium-modified gray cast iron brake discs were developed. Niobium additions of 0.11%, 0.17% and 0.26% to the chemical composition of a commercial gray cast iron were studied. The brake discs were cast and machined to final dimensions and finish for application. The microstructure was evaluated using an optical microscope and digital image analysis software. Braking performance and wear test were performed on an inertia dynamometer. Non-destructive testing was conducted using penetrating liquids to reveal cracks after the braking test. In addition, the generation of cracks due to cyclical mechanical and thermal stresses suffered by the discs during use was explained. With increasing the Nb addition, there was a tendency to increase the friction stability and settlement speed, a decrease in the braking temperature and a reduction of wear loss. The addition of niobium improved the behavior of the brake discs, mainly in reducing the wear of the friction pair, 31% for the disc and 15.5% for the pads. The best results were found with disc 4 containing 0.26% Nb.

Keywords
Disc brake; Gray cast iron; Niobium; Wear; Thermal fatigue; Braking performance