Investigation on tribological and corrosion characteristics of oxide-coated steel and mild steel fiber-based brake friction composites

2019 ◽  
Vol 71 (3) ◽  
pp. 341-347 ◽  
Author(s):  
Manoharan S. ◽  
Vijay R. ◽  
Lenin Singaravelu D. ◽  
Mohamed Kchaou
Keyword(s):  
Corrosion Resistance ◽  
Mild Steel ◽  
Oxide Coating ◽  
Steel Fibers ◽  
Coated Steel ◽  
Content Type ◽  
Brake Pads ◽  
Normal Water ◽  
Industrial Standards ◽  
Worn Surface

PurposeThe purpose of this work is to investigate the effect of oxide-coated steel in comparison with mild steel fibers on the tribological and corrosion performances of friction composites.Design/methodology/approachIn this study, the friction composites were developed in the form of standard brake pads by using oxide-coated steel and compared with mild steel fibers-based one without varying the other ingredients. The brake pads were developed as per the industrial procedure. The physical, mechanical, thermal properties of the developed brake pads were analyzed as per the industrial standards. The tribological properties were analyzed using the Chase test. The worn surface analysis was done using scanning electron microscope. Corrosion behavior was also analyzed in both salt and normal water conditions.FindingsThe experimental results indicate that the oxide-coated steel-based friction composites brake pads possess good physical, chemical, thermal, corrosion resistance and mechanical properties with stable fade and recovery characteristics because of its oxide coating and flake morphology.Originality/valueThis paper explains the influence of oxide-coated steel in friction composites for enhancing the tribological performance and corrosion resistance by its oxide coating and flake morphology which could potentially replace mild steel fibers-based problems in friction composites.

Influence of natural barytes purity levels on the tribological characteristics of non-asbestos brake pads

2019 ◽  
Vol 72 (3) ◽  
pp. 349-358 ◽  
Author(s):  
Vijay R. ◽  
Manoharan S. ◽  
Lenin Singaravelu D.
Keyword(s):  
Tribological Performance ◽  
Impurity Level ◽  
Mechanical And Thermal Properties ◽  
Industrial Practice ◽  
Content Type ◽  
Brake Pads ◽  
Purity Level ◽  
Brake Dynamometer ◽  
Industrial Standards ◽  
Worn Surface

Purpose This paper aims to deal with the effect of natural barytes purity levels on the tribological performance of brake pads. Design/methodology/approach In this study, brake pads were developed by varying three different natural barytes without varying other ingredients. The brake pads were developed as per the standard industrial practice. The physical, mechanical and thermal properties of the developed brake pads were tested as per the industrial standards. The tribological properties were analyzed using a full-scale inertia brake dynamometer. Worn surface analysis was done using scanning electron microscope coupled with elemental mapping. Findings The experimental results indicate that the brake pads filled with natural barytes 95% purity had good physical, chemical and mechanical properties with stable friction and less wear rate due to reduced impurity level preventing frictional undulations. Originality/value This paper explains the effect of the purity level of natural barytes in brake pads formulation to enhance the tribological performance by altering tribofilms and preventing friction undulations.

Tribological Performance of a Non Asbestos Organic Brake Pad Using Various Organic and Mineral Fibers

2012 ◽  
Vol 585 ◽  
pp. 559-563
Author(s):  
M.A. Sai Balaji ◽  
K. Kalaichelvan
Keyword(s):  
Wear Behavior ◽  
Testing Machine ◽  
Brake Disc ◽  
Brake Pads ◽  
Degradation Temperature ◽  
Industrial Standards ◽  
Worn Surface ◽  
Acrylic Fibers ◽  
Automotive Brake

Non-Asbestos organic composite friction materials are increasingly used in automotive brake disc pad applications. The present paper deals with the role of various organic fibers Kevlar, Acrylic fibers and the Rock fiber namely the Lapinus fiber on the fade and recovery behavior of friction composites. Three different friction composites were developed with same formulation varying only the percentage of Kevlar, Acrylic and lapinus fibers within the formulation. The formulations containing 13.5% of these fibers were developed as brake pads and designated as NA01, NA02 and NA03 respectively. The chemical and Mechanical properties are tested as per Indian Industrial standards.. The composites are then tested for the tribo-performance using Chase Testing Machine following SAE J661a standards. The fade µ, recovery µ and wear are significantly influenced by the amount and type of fiber combinations. Also the TGA reveals the degradation temperature of these fibers. Composite NA 03 containing Kevlar and lapinus combination is found to have good tribo performance. Worn surface analysis by SEM has proved to be useful in understanding the wear behavior of the composites.

Effects of potassium silicate on corrosion behavior of dacromet coating

2019 ◽  
Vol 66 (6) ◽  
pp. 819-826
Author(s):  
Khashayar Tabi ◽  
Mansour Farzam ◽  
Davood Zaarei
Keyword(s):  
Corrosion Resistance ◽  
Corrosion Behavior ◽  
Automobile Industry ◽  
Electrochemical Impedance ◽  
Salt Spray ◽  
Corrosion Current ◽  
Potassium Silicate ◽  
Coated Steel ◽  
Content Type ◽  
New Information

Purpose Potassium silicate sealer was applied on solvent-cleaned, acid-pickled, dacromet-coated steel to improve its corrosion resistance. The purpose of this paper is to study the corrosion behavior of dacromet-coated steel. Design/methodology/approach Potassium silicate sealer was applied on solvent-cleaned, acid-pickled, dacromet-coated steel to improve its corrosion resistance. Electrochemical impedance spectroscopy (EIS), potentiodynamic polarization, scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS) and salt spray were carried out. SEM was used to study the morphological appearance of the surface. Findings The EIS behavior indicated that solvent-cleaned dacromet-coated steel sealed with potassium silicate showed that the corrosion current density was 2.664E − 5 A.cm2 which was reduced to 8.752E − 6 A.cm2 and the corrosion rate, which was 2.264E − 2 mm.year−1, was reduced to 7.438E − 3 mm.year−1 in NaCl 3.5 wt.per cent. EIS was used in NaCl 3.5 wt.%, and the Bode plot characteristics showed that the corrosion protection of solvent-cleaned, dacromet-coated steel was enhanced when sealed with potassium silicate. The EDS results of salt-sprayed, solvent-cleaned samples after 10 days indicated that the main corrosion products are composed of SiO2, ZnO and Al2O3. Research limitations/implications The detection of Li element in EDS was not possible because of the device limitation. Originality/value The current paper provides new information about the sealing properties of potassium silicate and its effects on the corrosion resistance of dacromet coating, which is widely used in many industries such as the automobile industry.

Fabrication of renewable myristic acid based polyurethane nano zinc phosphate hybrid coatings to mitigate corrosion of mild steel

2018 ◽  
Vol 47 (2) ◽  
pp. 97-107 ◽  
Author(s):  
Sandip D. Rajput ◽  
Chandrashekhar K. Patil ◽  
Vikas V. Gite
Keyword(s):  
Corrosion Resistance ◽  
Mild Steel ◽  
Myristic Acid ◽  
Zinc Phosphate ◽  
Corrosion Properties ◽  
One Pot ◽  
Renewable Source ◽  
Content Type ◽  
Nano Rods ◽  
Nano Zinc

Purpose The present study aims to demonstrate the use of renewable source in the preparation of polyurethane (PU) coatings and mitigation of corrosion of mild steel using nano zinc phosphate. Results indicated improvement in the properties of the PU coatings, especially anticorrosive properties by the addition of nano zinc phosphate. Design/methodology/approach Renewable-source-based polyestermyristamide polyol was synthesized using myristic acid as a starting material. The synthesis of polyol was carried by amidation as well as by esterification by a one-pot route. The structure of the prepared polyestermyristamide was confirmed with the support of end-group analysis and spectral study. PU coatings were prepared from synthesized polyestermyristamide polyol and used to protect metal substrate against corrosion. Corrosion properties of the prepared PU were found to be lower; hence, to improve the performance of these coatings, nano zinc phosphate was added to the coatings. The nano zinc phosphate was synthesized in the laboratory by reported sonication method and analyzed for morphology by scanning electron microscopy. Performance of coatings was studied with respect to effect of percentage nano zinc phosphate on thermal stability, mechanical properties and chemical resistances of PU coatings. Findings The combination of zinc phosphate nano rods and particles in myristic acid-based PU coatings provided substantial corrosion barrier properties to the coatings. Different per cent of the synthesized zinc phosphate nano rods and particles were loaded into the matrix, and corresponding coatings were estimated for corrosion resistance, thermal and chemical properties. Immersion study of the coated panels in 3.5 per cent NaCl solution showed good corrosion resistance for both PU coatings containing 2 and 3 per cent nano zinc phosphate. Practical implications This paper has provided the solution to replace existing petroleum-based raw materials with myristic acid as a renewable source in preparing PU coatings. Conventional coatings act as physical barriers against aggressive species but do not have ability to perform as permanent impassable to corrosive species. Hence, nano-sized zinc phosphate is used as corrosion inhibitor in to the synthesized PU coatings for enhancing anticorrosive performance. Originality/value In the paper, polyesteramide polyol is synthesized using renewable-source-based material, i.e. myristic acid to replace existing petroleum-based acid as a greener approach. Normally, vegetable oils are preferred as they have such kinds of polyols. The polyesteramide reaction is one pot that avoids the extra steps required in the synthesis. Further, it has been found that the pristine renewable coatings are unable to fully protect subtract from corrosion, whereas an addition of the nano-size zinc phosphate has enhanced the corrosion properties of the coatings.

Synergistic effect of Steel Slag-Molybdenum disulfide particles on fade-recovery performances of non-asbestos organic friction material

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Sundarrajan D. ◽  
Pitchipoo Pandian ◽  
Manoharan Sembian
Keyword(s):  
Synergistic Effect ◽  
Peer Review ◽  
Molybdenum Disulfide ◽  
Steel Slag ◽  
Friction Material ◽  
Mechanical And Thermal Properties ◽  
Friction Materials ◽  
Content Type ◽  
Brake Pads ◽  
Industrial Standards

Purpose This paper aims to deal with the synergistic effect of steel slag-molybdenum disulfide particles on fade-recovery performances of non-asbestos organic friction material. Design/methodology/approach The brake friction materials were developed by using steel slag and molybdenum disulfide particles as individual and combination in the formulation. The brake friction materials were developed in the form of standard brake pads as per the industrial practice. The physical, mechanical and thermal properties of the developed brake pads were tested as per the industrial standards. The tribological properties were analyzed using the Chase test as per IS2742-Part-4. Worn surface analysis was done using a scanning electron microscope. Findings The experimental results indicate that the brake pads filled with a combination of steel slag and molybdenum disulfide showed stable friction and less wear rate due to the synergetic nature of abrasive and lubricant. Originality/value This paper explains the influence of steel slag and molybdenum disulfide particles as individual and combined in brake pads formulation to enhance the tribological performance by producing stabilized friction with undulations. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2020-0216/

New corrosion inhibitors based on epoxidized natural rubber for coating protection of metals under UV irradiation

2017 ◽  
Vol 64 (4) ◽  
pp. 389-396 ◽  
Author(s):  
Issa Mousaa ◽  
Hamdi Radi
Keyword(s):  
Weight Loss ◽  
Mild Steel ◽  
Natural Rubber ◽  
Metal Surface ◽  
Uv Irradiation ◽  
Corrosion Inhibitors ◽  
Epoxidized Natural Rubber ◽  
Coated Steel ◽  
Content Type ◽  
Coating Formulations

Purpose In the present work, under severe conditions of an inert atmosphere and high temperature, epoxidized natural rubber (ENR) with 25 per cent epoxidation level reacts with different aliphatic amine compounds such as ethyl amine (EA), propyl amine (PA) and butyl amine (BA) to prepare ENR/EA, ENR/PA, ENR/BA compounds as, respectively. The produced compounds were characterized by Fourier transform infrared spectroscopy and oxirane oxygen content determination. Different concentrations of the produced compounds were added to epoxy and urethane acrylate coating formulations to evaluate them as corrosion inhibitors for mild steel under UV irradiation. Corrosion resistance tests and weight loss measurements of the coated steel panels were made. It was found that coating formulations containing the prepared ENR/EA compound could protect metal surface from corrosion, and corrosion inhibitors efficiency of the prepared compounds were arranged as follows: ENR/EA > ENR/PA > ENR/BA. The optimum concentrations for all inhibitors which give the best inhibition efficiency for corrosion are 0.4-0.6 phr. Design/methodology/approach Corrosion scratch tests were carried out according to ASTM D 1,654-92 (2000). The weight loss of coated steel was measured according to ASTM D 2,688-94 (1999). The measurement of film hardness was carried out with a Wolff–Wilborn pencil hardness tester according to ASTM D 3,363 (2000). Findings It was found that coating formulations containing the prepared ENR/EA compound could protect metal surface from corrosion and corrosion inhibitors efficiency of the prepared compounds were arranged as follows: ENR/EA > ENR/PA > ENR/BA. The optimum concentrations for all inhibitors are 0.4-0.6 g/100g coating. Originality/value A highly efficient and economically corrosion inhibitors for mild steel were prepared from ENR and series of aliphatic amines.

Electrochemical property analysis of SiO2-Al2O3-coated steel by electrochemical impedance spectroscopy

2017 ◽  
Vol 64 (4) ◽  
pp. 365-370 ◽  
Author(s):  
Sebahattin Kirtay
Keyword(s):  
Corrosion Resistance ◽  
Electrochemical Impedance Spectroscopy ◽  
Impedance Spectroscopy ◽  
Electrochemical Impedance ◽  
Sol Gel ◽  
Dip Coating ◽  
Coated Steel ◽  
Content Type ◽  
Coated Materials ◽  
Uncoated Specimen

Purpose The purpose of this paper is to investigate the corrosion resistance of SiO2-Al2O3 coating on mild steel. Design/methodology/approach SiO2-Al2O3 was coated using sol-gel method, and electrochemical measurements were applied to assess the performance of the coated steel. Findings The main conclusion is that SiO2-Al2O3-coated specimens acquired a higher corrosion resistance than that of uncoated specimen. icorr values of the coated specimens were between 12 and 14 times smaller than those of uncoated specimen. The coated specimens exhibited a higher Rcor value at electrochemical impedance spectroscopy analysis. The high values of Rcor and low values of CPEdl observed within the SiO2-Al2O3-coated samples imply an improved anti-corrosion capability. Originality/value In this work, there are three points of originality. First, steel specimens were coated with ormosil-based solution by applying sol-gel dip coating method. Second, both SiO2 and Al2O3 coatings were applied simultaneously at a considerably low temperature, i.e. 200 °C. Finally, the performance of the coated materials against wet corrosion was improved significantly.

Corrosion investigation of Co–Ni–Fe-coated mild steel electrodeposited at different current densities and deposition times

2017 ◽  
Vol 69 (3) ◽  
pp. 393-398 ◽  
Author(s):  
Mei Hyie Koay ◽  
Mohd Adham Akmal Tukiran ◽  
Siti Nur Amalina Mohd Halidi ◽  
Mardziah Che Murad ◽  
Zuraidah Salleh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Corrosion Resistance ◽  
Corrosion Rate ◽  
Mild Steel ◽  
Current Density ◽  
Steel Substrate ◽  
Low Cost ◽  
Future Application ◽  
Processing Parameter ◽  
Content Type

Purpose The purpose of this study is to determine the effect of current density on the surface roughness and corrosion performance of electrodeposited Co–Ni–Fe-coated mild steel. Process variables are the key factor in controlling the electrodeposition process. It is important to study the processing parameter to optimize the mechanical and corrosion resistance performance of the coating substrate. Design/methodology/approach A low-cost electrodeposition method was used to the synthesize Co–Ni–Fe coating on the mild steel substrate. In the electrodeposition, electrochemistry concept was applied. The temperature of the process was controlled at 50 ± 5°C in an acidic environment. The influence of current density (11, 22 and 33 mA/cm2) and deposition time (15, 20 and 30 min) toward the surface roughness, hardness and corrosion rate was investigated. Findings The increases of time deposition and current density have improved the microhardness and corrosion resistance of Co–Ni–Fe-coated mild steel. The Co–Ni–Fe nanoparticles deposited at 30 min and current density of 33 mA/cm2 experienced the smallest surface roughness value (Ra). The same sample also obtained the highest Vickers microhardness of 122.6 HV and the lowest corrosion rate. This may be due to the homogenous and complete protection coating performed on the mild steel. Practical implications The findings from the study are important for future application of Co–Ni–Fe on the mild steel parts such as fasteners, car body panels, metal chains, wire ropes, engine parts, bicycle rims, nails and screws and various outdoor uses. The improvement of corrosion resistance using optimum electrodeposition parameters is essential for these applications to prolong the life span of the parts. Originality/value A new process which pertains to fabrication of Co–Ni–Fe as a protective coating on mild steel was proposed. The Co–Ni–Fe coating can enhance the corrosion protection and thus prolong the lifespan of the mild steel parts.

Influence of iron–aluminum alloy on the tribological performance of non-asbestos brake friction materials – a solution for copper replacement

2019 ◽  
Vol 72 (1) ◽  
pp. 66-78 ◽  
Author(s):  
Saikrishnan G. ◽  
Jayakumari L.S. ◽  
Vijay R. ◽  
Lenin Singaravelu D.
Keyword(s):  
Aluminum Alloy ◽  
Tribological Performance ◽  
Mechanical And Thermal Properties ◽  
Initial Speed ◽  
Content Type ◽  
Aluminum Powders ◽  
Brake Pads ◽  
Iron Aluminum ◽  
Brake Dynamometer ◽  
Industrial Standards

Purpose The purpose of this study is to investigate the influence of commercially available iron–aluminum alloy compared to copper, iron and aluminum powders on the tribological performances of friction composites. The main objective is to replace copper from the friction composite formulations. Design/methodology/approach In this study, friction composites were fabricated as of standard brake pads using commercially available iron–aluminum alloy and compared to copper powder, iron powder and aluminum powder-based without varying the other ingredients. The brake pads were developed as per the industrial procedure. The physical, mechanical and thermal properties of the developed brake pads were analyzed as per industrial standards. Tribological properties were analyzed using the chase test. Initial speed and deceleration tests in a real-time braking scenario were performed using a full-scale inertia brake dynamometer. Worn surface analysis was done using a scanning electron microscope. Findings The results indicate that iron–aluminum alloy (mechanomade)-based friction composites possess good physical, chemical, thermal and mechanical properties with stable fade and recovery characteristics due to its composition and flake morphology. During initial speed and deceleration braking conditions, iron–aluminum alloy also showed good tribological behavior. Originality/value This paper explains the influence of commercially available iron–aluminum alloy in friction composites in enhancing tribological performance by its composition and flake morphology, which could potentially replace copper in friction composites by solving subsequent problems.

The effect of vibratory conditioning on tensile strength and microstructure of 1018 mild steel

2020 ◽  
Vol 17 (6) ◽  
pp. 837-844 ◽  
Author(s):  
Venkata Suresh Bade ◽  
Srinivasa Rao P. ◽  
Govinda Rao P.
Keyword(s):  
Tensile Strength ◽  
Mild Steel ◽  
Fusion Zone ◽  
Dc Motor ◽  
Grain Structure ◽  
Internal Stresses ◽  
Skilled Workers ◽  
Mechanical Vibrations ◽  
Content Type ◽  
Weld Defects

Purpose The purpose of this paper is to investigate the prominence of mechanical excitations at the time of welding. In the past years, the process of welding technology has expanded its influence in manufacturing. The crucial drawback of conventional welding is prompted by internal stresses and distortions, which is the focal reason for weld defects. These weld defects can be diminished by the process called post-weld heat treatment (PWHT), which consumes more working hours and needs skilled workers. To replace these PWHT processes, mechanical vibrations are introduced during the process of welding to diminish these weld defects. Design/methodology/approach In the current research, the mechanical vibrations are transferred to weld-pool through vibro-motor and DC motor connected to the electrode. As per standards, the tensile test specimens were prepared for welding with different voltages of vibro-motor and DC motor respectively. The weld joints were tested for tensile strength and analyzed the microstructure at the fusion zone. Findings Melt-ability at fusion zone of 1018 mild steel was investigated by the single-stroke intense heat process of fusion welding. It is observed that the mechanical vibrations technique has a profound influence on the enhancement of the fusion zone characteristics and grain structure. The peak value of the tensile strength is observed at 100 s of vibration, 190 V of vibro-motor voltage and 18 V of electrode voltage. The tensile strength of the welded joints with vibrations is increased up to 22.64% when it is compared with conventional welding. The enhancement of the tensile strength of the weld bead was obtained because of the formation of fine grain structure. So, mechanical vibrations are identified as the most convenient method for improving the mild steel alloys weld quality. Originality/value A novel approach called mechanical vibrations during the process of welding is implemented for fusion zone refinement.

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