The Influence of SiC and Al₂O₃ Particles on the Microstructure and Tribological Properties of the EN-GJL-150 Cast...

This article presents preliminary research on the development of a cast iron-ceramic composite for modern braking systems, such as brake discs. The composite matrix is gray cast iron with flake graphite (EN-GJL-150). The reinforcing phase is a porous ceramic composed of SiC and Al₂O₃ particles introduced separately (10% each) and together (70% SiC + 30% Al₂O₃). These particles were applied as a suspension onto polyurethane foam, yielding a ceramic structure with a pore density of up to 10 ppi. The resulting insert was placed in a mold cavity, and cast iron was poured into it. The resulting samples were treated as brake disc material, with a pad made of the commercial friction material P50094 serving as the countersample. Tribological tests showed that the lowest sample wear (average 2.23 mg/5000 m) was achieved for the composite reinforced with SiC + Al₂O₃ particles. This is probably due to the synergy between the antifriction properties of these particles and the lower friction coefficient (µ = 0.180-0.22). Similar mass loss values and the smallest difference between the tested samples were observed for composites with SiC particles (3.01 mg/5000 m) and Al₂O₃ (3.30 mg/5000 m). The second part consisted of microstructural studies. Microstructural analysis of the EN-GJL-150 + SiC + Al₂O₃ composite revealed a previously unobserved nucleation phenomenon at the cast iron-ceramic interface. This confirmed the general assumptions of Riposan's theory regarding the involvement of oxide microinclusions and complex manganese sulfides of the (Mn, X)S type in the nucleation and crystallization of graphite precipitates. It was also found that, in the case of "in situ" GJL-150 + SiC + Al₂O₃ composites, this theory should account for the beneficial role of ceramic particles in promoting the uniform distribution of type A graphite flakes, which nucleate on their surfaces in the transition zone. Thus, the nucleating role of oxide microinclusions (the first stage of Riposan's theory) could be taken over by SiC and Al₂O₃ particles, constituting a substrate for the heterogeneous nucleation of (Mn, X)S sulfides.