Development and characterisation of iron millscale particle reinforced ceramic matrix composite

The quest for quality brake pads for use in aircrafts and automobiles to ensure effectiveness and safety continues to attract attention. Hence, this study was carried out as part of the global efforts at tackling the problem of the low durability of these friction materials. An iron millscale (IMS) particle reinforced ceramic matrix composite (CMC) was developed by the powder metallurgy method and characterised. The IMS particle addition varied from 5-30 wt.% in each CMC produced at different particle size distributions (106-250 μm) using silica (SiO2), magnesia (MgO), and sodium bentonite as matrices. On the basis of the close correlation between structure and property, the CMCs were subjected to physical, mechanical, and microstructural characterisation using X-ray Fluorescence (XRF), X-ray Diffraction (XRD), and Scanning Electron Microscopy with Energy Dispersive Spectroscopy (SEM/EDS). The composite exhibits desirable physical and mechanical properties in terms of density (2.97 g/cm3), porosity (1.24%), linear shrinkage (1.39%), impact energy (43.07 J), and compressive strength (114.17 MN/m2). These values compare very well with the values of brake pads obtained in previous studies and conventional/commercial brake pads, indicating a potential for effective performance in service.