Ceramic waste SiC particle-reinforced Al matrix composite brake materials with a high friction coefficient

We investigated wear behavior of ceramic waste SiC particle-reinforced aluminum matrix composites (ASC) to evaluate the effect of hybrid particles on dry sliding. Aluminum alloy and its composites were prepared by powder metallurgy process. Brinell hardness and flexural strength of ASC are improved compared to those of the aluminum base alloy. When the load increases to 80 N, the friction coefficient of ASC increases by 32% compared to that of only SiC-reinforced aluminum matrix composites. The wear rate is similar to that of the SiC-reinforced aluminum matrix composites, and only 1/15 of that of the conventional brake disc material (HT250). Results of scanning electron microscopy, X-ray photoelectron spectroscopy, and grazing incidence X-ray diffraction showed that the ceramic waste particles are involved in the formation of a mechanical transfer layer of ASC. This layer is favorable for the preservation of ultrafine wear debris over the worn surface. Hybrid particles effectively protect the matrix and provide a high friction coefficient. ASC is a potential candidate material for high-performance brake discs.