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<p>Fe-Cu-based sintered friction materials are promising candidates for wind turbine brake pads. This study investigates the effect of varying graphite (Cg) contents on the wear mechanism and debris characteristics of Fe/Cu-ZrSiO<sub>4</sub> composites. Samples were fabricated via powder metallurgy with Fe–Cu as the matrix, reinforced with BaSO<sub>4</sub> (5&#xa0;wt.%), ZrSiO<sub>4</sub> (5 wt.%), and C<sub>g</sub> (1-7&#xa0;wt.%). Microstructural analysis confirmed homogeneous dispersion of reinforcements within the matrix. The ZG03 composition (3&#xa0;wt.% Cg) achieved the highest microhardness of 170.3 HV and compression strength of 263&#xa0;MPa, while ZG05 (5&#xa0;wt.% Cg) exhibited the lowest wear rate and stable friction coefficient. The detailed morphology of the worn surface and wear debris was characterized using FESEM and EDS. Phase and chemical analyses through XRD elucidated the wear mechanisms. The main wear mechanisms are abrasive and oxidative wear, influenced by the uniform dispersion of C<sub>g</sub> and the synergistic effect of hard reinforcements. The study highlights the critical role of C<sub>g</sub> in tailoring the performance of Fe–Cu-based friction materials.</p>

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Powder Metallurgy Processed Graphite and ZrSiO4 Reinforced Fe-Cu/BaSO4 Sintered Composites for Wind Turbine Friction Applications

  • 期刊论文

  • 发表日期：

    2026年5月20日

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  • K. Rajesh Kannan,
  • Sudheer Reddy Beyanagari,
  • R. Vaira Vignesh,
  • M. Govindaraju,
  • G. Suganya Priyadharshini,
  • Karthik V Shankar

摘要

Fe-Cu-based sintered friction materials are promising candidates for wind turbine brake pads. This study investigates the effect of varying graphite (Cg) contents on the wear mechanism and debris characteristics of Fe/Cu-ZrSiO4 composites. Samples were fabricated via powder metallurgy with Fe–Cu as the matrix, reinforced with BaSO4 (5 wt.%), ZrSiO4 (5 wt.%), and Cg (1-7 wt.%). Microstructural analysis confirmed homogeneous dispersion of reinforcements within the matrix. The ZG03 composition (3 wt.% Cg) achieved the highest microhardness of 170.3 HV and compression strength of 263 MPa, while ZG05 (5 wt.% Cg) exhibited the lowest wear rate and stable friction coefficient. The detailed morphology of the worn surface and wear debris was characterized using FESEM and EDS. Phase and chemical analyses through XRD elucidated the wear mechanisms. The main wear mechanisms are abrasive and oxidative wear, influenced by the uniform dispersion of Cg and the synergistic effect of hard reinforcements. The study highlights the critical role of Cg in tailoring the performance of Fe–Cu-based friction materials.