Synthesis and characterisation of iron millscale particles reinforced ceramic matrix composite

摘要

A promising sintered particulate ceramic matrix composite suitable for automobiles and aircrafts brake pad application was developed by powder metallurgy method in an attempt to enhance the performance and service life of the brake pad. The detailed methodology involves using formulation of 30wt% silica, 40wt% magnesia, and 30wt% bentonite as matrices. The blended matrix was reinforced with iron millscale particles which varied from 3 to 18wt% at particles size distribution (106–250)μm. The developed composites were subjected to physical, mechanical, thermal, wear, and microstructural characterisations using Scanning Electron Microscopy with Energy Dispersive Spectroscopy (SEM/EDS). Microstructure of the composite shows a uniform distribution of millscale particles in the ceramic matrix with a strong interfacial bonding between the particles. The composite exhibits desirable properties in terms of density (2.06g/cm3), hardness (124 BHN), impact energy (4.61J), compressive strength (143.67MN/m2), shear strength (5.78MN/m2), thermal conductivity (0.39W/mK), and wear rate (1.91×10?6g/m). These values compare well with the properties exhibited by conventional/commercial brake pads indicating a potential for effective performance in service.