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Effect of MoS2 Nanoflakes on Mechanical and Tribological Behavior of Composite Friction Material Fabricated by Pressure-Assisted Sintering

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Abstract

The MoS2 nanoflakes can be a novel candidate as a solid lubricant in fabricating friction material for automotive brake-pad disc systems. In this paper, an investigation has been made to analyze the effect of MoS2 nanoflakes on the mechanical and tribological behavior of the formulated copper-free low-metallic composite friction material. Three samples, namely S1, S2, and S3, have been fabricated containing different types of solid lubricant. Sample S1 had a solid lubricant as graphite, while samples S2 and S3 had graphite mixed with solid lubricant MoS2 with average flake sizes of 2 µm and 50 nm, respectively. Other components included steel, PAN, and aramid as reinforcing fibers; walnut powder, barium sulphate (BaSO4), and nitrile-butadiene rubber as fillers; phenolic resin as a binder; and FeO, Quartz, and MgO as abrasives. A pin-on-disc tribometer test (ASTM G-99) was conducted to carry out the wear test at a load of 60 N, sliding velocity of 2.09 m/s, and sliding distance of 6283 m at room temperature. A scanning electron microscope was used to study the micro-structural evolution of worn composite friction pin material. The results show that the nano-sized MoS2 solid lubricant influences the structural integrity of the formulated composites, which governs the friction and wear behavior. The graphite and MoS2-based friction composites S2 and S3 perform better than the conventional friction material (S1) containing graphite in terms of physical–mechanical, thermal, and tribological properties. The specific wear rate of the S1 sample is the highest (2.72 × 10–5 mm3/Nm) followed by S2 (1.84 × 10–5 mm3/Nm) and S3 (0.98 × 10–5 mm3/Nm) respectively. The graphite and MoS2-based friction specimens S2 and S3 showed adequate coverage of friction plateaus, reducing wear and abrasion of the counter disc.

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Data availability

The datasets used and/or analyzed during the current study are available from the corresponding author upon reasonable request.

Abbreviations

CoF:

Coefficient of friction

GCI:

Grey cast iron

SEM:

Scanning electron microscope

EDX:

Energy dispersive X-ray spectroscopy

XRF:

X-ray fluorescence spectroscopy

ρ :

Density of pin

W 1 :

Initial pin weight

W 2 :

Final pin weight

NBR:

Nitrile-butadiene

PoD:

Pin-on-disc

P :

Porosity (%)

w f :

Weight of the sample after soaking in water for 24 h

w i :

Initial weight of the sample

K a :

Specific wear rate

F :

Force

W :

Wear rate

MoS2 :

Molybdenum disulfide

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Acknowledgements

The authors thank the BITS Pilani Hyderabad campus central library for providing access to different journals and Central Analytical Laboratory (CAL) for SEM access.

Funding

The research has received partial funding from the Science and Engineering Research Board (SERB), Government of India, under the Accelerate Vigyan-Vritika scheme with file no. AV/VRI/2022/0013.

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Authors and Affiliations

  1. Department of Mechanical Engineering, BITS Pilani, Hyderabad Campus, Secunderabad, 500078, India

    Ashish Saurabh, Abhinav Manoj, Tarun Boni, Tarini Ranjan Pradhan, Ullas Basavaraj, Prabakaran Saravanan & Piyush Chandra Verma

  2. Department of Mechanical Engineering, FGIET, Raebareli, 229001, India

    Ashiwani Kumar

  3. Sir Lawrence Wackett Defence and Aerospace Centre, School of Engineering, RMIT University, Melbourne, Victoria, 3000, Australia

    Raj Das

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  1. Ashish Saurabh
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Contributions

AS: Visualization, Methodology, Investigation, Validation, Writing an original draft, Data curation. AM: Investigation, Data curation, Writing an original draft. TB: Methodology, Investigation. TRP: Investigation, Data curation. UB: Investigation, Data curation. PS: Methodology, Investigation, Writing review, and editing. AK: Investigation, Writing an original draft. PCV: Writing review and editing, Fund acquisition, Conceptualization, Supervision.

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Correspondence to Piyush Chandra Verma.

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Saurabh, A., Manoj, A., Boni, T. et al. Effect of MoS2 Nanoflakes on Mechanical and Tribological Behavior of Composite Friction Material Fabricated by Pressure-Assisted Sintering. Met. Mater. Int. 30, 697–713 (2024). https://doi.org/10.1007/s12540-023-01519-2

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