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Evaluation of a Cast Al-Mg2Si Composite for Automobile Disk-Brake Rotor Application

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Abstract

This investigation involved the development and characterization (microstructure, mechanical properties, and dry sliding wear characteristics) of Al-Mg2Si composites for automobile applications. Consequently, the performance analysis of the Al-Mg2Si composites was conducted considering motorcycle disk brake rotor application. The digital logic method (DLM), a material selection process, was employed to compare the performance of Al-Mg2Si composites with traditional rotor materials, cast iron, and stainless steel. The motorcycle disk brake operation was simulated with steel and Al-20wt.% Mg2Si composite rotor to establish the findings of performance analysis. The DLM analysis revealed that the Al-20wt.% Mg2Si composite had a technical performance index of 73.65, while steel had a technical performance index of 78.10. Additionally, the energy efficiency index (EEI) for the composite and steel stood at 31.79 and 100, respectively. Furthermore, the composite exhibited much lower CO2 and CO emissions compared to steel, with values of 0.087 and 0.0026 g/km versus 0.276 and 0.0082 g/km, respectively. The simulation results indicated that both the stainless steel and the Al-20Mg2Si composite rotor exhibited structural suitability. In the Al-20Mg2Si composite rotor, the induced temperature ranged from 35.4 to 60.3 °C, while the heat flux ranged from 1.462 × 103 to 3.64 × 105 W/m2. On the other hand, the stainless steel rotor experienced induced temperature ranging from 41.55 to 87.4 °C, and heat flux ranging from 4.0 × 102 to 1.64 × 105 W/m2. The composite rotor demonstrated a lower induced temperature and higher heat flux, which in turn reduced the probability of both direct and indirect thermal damage and improved structural integrity.

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The raw/processed data required to reproduce these findings cannot be shared at this time as the data also form part of an ongoing study.

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Funding

The author(s) received financial support for this research work from the Science & Engineering Research Board (SERB), India, SERB Sanction Order No: EEQ/ 2018/000592.

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  1. Department of Metallurgical and Materials Engineering, National Institute of Technology, Durgapur, Durgapur, West Bengal, 713209, India

    Prosanta Biswas & Manas Kumar Mondal

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  1. Prosanta Biswas
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PB contributed to conceptualization, methodology, formal analysis, investigation, writing—original draft. MKM contributed to conceptualization, funding acquisition, resources, supervision, writing—review & editing.

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Correspondence to Manas Kumar Mondal.

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Appendix 1: Digital Logic Method (DLM)

Appendix 1: Digital Logic Method (DLM)

Details of the calculation done to obtain the Performance Index (γ) considering the DLM are presented in this Appendix. The DLM is a material selection technique similar to the ranking method introduced by Morris (1964) (Ref 115). Every possible pair of essential material properties is appraised according to application importance by utilizing a binary score of one (1) or zero (0). When comparing a particular pair of properties, the more important property gets a positive decision of one (1), and another one gets Zero (0). The total number of positive decisions (N) has been calculated according to Eq 1.

$$N = \frac{{n\left( {n - 1} \right)}}{2}$$
(1)

where n denotes the number of effective properties to be considered for selecting material for the disk brake rotor. In the present study, the total number of necessary properties is seven (n = 7), as shown in Table 3. The total number of positive decisions in the present case is:

$$N = \frac{{7\left( {7 - 1} \right)}}{2} = 21$$

After comparing all the possible pairs and assigning the binary code one (1) or zero (0), results are presented in a matrix form as shown in Table

Table 6 Determination of relative importance of properties for disk brake rotor using digital logic method (DLM), where ‘1, 2, 3,…..21’ denote positive decision and ‘P1, P2, …P7’ denote materials properties
Full size table

6. The total number of positive decisions for individual properties (Np) was counted, and a weighting factor/ relative emphasis coefficient (α) are calculated according to Eq 2.

$$\alpha = \frac{{N_{P} }}{N}$$
(2)

Relative emphasis coefficient (α) is a weighted property comparing a pair of properties of a particular material. The calculated relative emphasis coefficient (α) is shown in Table

Table 7 Relative Emphasis Coefficient (α) of considered properties for disk brake rotor materials
Full size table

7. To consider the emphasis of a material, the weighted properties method was applied to calculate the scaling factor (β). There are two types of properties: for some properties, high values have a positive impact (strength), while for other properties, low values have a positive impact (density) on the disk brake rotor application. If the maximum value is desirable, then for a particular property highest value material scaling factor (β) will be 100, and if the minimum value is desirable, then the lowest value material scaling factor (β) will be 100 as shown in Table

Table 8 Calculated scaling factor (β) for the required properties of the disk brake rotor
Full size table

8.

When the maximum value is desirable, then the scaling factor (β) has been calculated using Eq 3.

$$\beta = \frac{{\text{Numerical\; value\; of\; property}}}{{\text{Maximum value in the list}}} \times 100$$
(3)

When the minimum value is desirable, then the scaling factor (β) is calculated using Eq 4.

$$\beta = \frac{{\text{Minimum\; value\; in\; the\; list}}}{{\text{Numerical value of property}}} \times 100$$
(4)

The performance index (γ) is the multiplication value of the scaling factor (β) and the corresponding relative emphasis coefficient (α). The performance indexes (γ) of materials are calculated according to Eq 5. The calculated performance indexes (γ) are represented in Table

Table 9 Calculated performance index (γ) of the existing and proposed materials for disk brake rotor
Full size table

9. Table 9 reveals that the stainless steel and Al-Mg2Si disk have more or less the same performance index, but cast iron has a much lower performance index compared to other materials.

Materials performance index

$$\gamma = \sum\limits_{i = 1}^{n} {\beta_{i} \overline{\alpha }_{i} }$$
(5)

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Biswas, P., Mondal, M.K. Evaluation of a Cast Al-Mg2Si Composite for Automobile Disk-Brake Rotor Application. J. of Materi Eng and Perform (2023). https://doi.org/10.1007/s11665-023-08760-1

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