Polytetrafluoroethylene and Aluminum Powder as an Alternative to Copper in Car Brake Composite Friction Materials—Part 2, Simulation Studies of Braking Process

Currently, most design solutions are disc brake systems, in which, during braking, the rotating disc, along with the wheel, rubs against stationary brake pads, converting kinetic energy into thermal energy released into the atmosphere. Brake pads are made of composite materials. One of the key components is copper. Its presence is crucial and plays a crucial role in friction materials. In this work, an attempt was made to replace copper, which is unfortunately harmful to both the environment and humans, with aluminum powder and polytetrafluoroethylene powder. Samples of the proposed prototype friction materials were manufactured, and their thermal and tribological properties were determined (research described in the previous work). Knowledge of the materials’ properties allowed for simulation studies. Calculations were prepared for three different scenarios. The results showed that the heating process using the proposed materials during braking is very similar to that of materials with a conventional composition. Of the materials tested, composition where copper was replaced by polytetrafluoroethylene and aluminum in a 4:1 ratio gave the most promising results. In tests, this material had the lowest maximum brake pad temperature values, which contributes to a reduced risk of fading. Also, by “pushing” thermal energy into the brake disc, it contributes to the fastest dissipation of this energy. This suggests that the materials can be used in real-world braking systems.