Replacing copper in composites with waste foundry sand: A novel approach for Cu-free resin-based braking material

Cu-free resin-based brake material filled with waste foundry resin-bonded sand (waste sand) was prepared using the hot-pressing method. The changes in the physical and chemical properties of Cu and waste sand during braking were investigated, and their role in resin-based composites was discussed. The effects of the content of waste sand on the hardness, impact strength, indentation hardness, elastic modulus, friction coefficient, wear rate, micro-scratch friction coefficient, scratch depth, residual depth, and wear mechanism of resin-based brake material were investigated. Cu-contained composites generate Cu2O when braking at high temperatures, which adversely affects the friction and wear properties. Compared to Cu, waste sand was found to be more favorable for the overall friction and wear properties of resin-based composites. This suggests that waste sand can be used as a substitute for Cu in brake material. Waste sand is beneficial for improving the friction coefficient and stability of brake material through the formation of a friction layer. This layer can significantly impact the wear mechanism of brake material, particularly at high temperature (250-350 celcius). The brake material with 10-15% waste sand indicates excellent heat-fade resistance.

Automated summary

The study investigated the use of waste foundry resin-bonded sand as a substitute for copper in resin-based brake material. It found that the waste sand was more favorable for improving the overall friction and wear properties of the material compared to copper. Waste sand benefited the material by forming a friction layer, leading to increased friction coefficient and stability. Brake material with 10-15% waste sand showed excellent heat-fade resistance.