Development and optimization of friction material used in wind turbines and heavy-duty industrial brake systems

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This project aims at generating scientific insights and advanced technical solutions for manufacturing of friction material composites utilizing the Powder Metallurgy (PM) process. The project is targeted at different types of friction materials related to clean energy generation in wind power stations. The project will be focused on the proper choice of raw materials, development of appropriate formulations and optimization of PM fabrication procedures for reducing manufacturing costs for small and medium size production runs. Possible metallurgical and engineering solutions are proposed and will be tested and optimized to address the present challenges to fulfil the physical, mechanical and tribological performances required for such applications. More specifically, the proposal is subdivided in three sub-projects. The first one will deal with the development of metallic brake pads for yaw brakes to replace the organic materials that are currently used (high maintenance). This application requires a material with a static friction coefficient of 0.08-0.2, high compressive strength to withstand the applied load, high shear strength to prevent delamination and shearing during movement under load and high wear resistance. The second sub-projects will seek to regroup the sintering and brazing operations into a single one. Brake pads dedicated to rotor brakes in power generating wind mills require that Cu-based cylinders be sintered and than brazed on steel back plates. The intent in this sub-project is to sinter the cylinders and braze them on the bake plates in a single operation, thus increasing productivity and decreasing energy consumption. The third sub-projects will focus on developing models to predict the friction performances of brake pad materials. Such models will serve to minimize development steps required to optimize the friction performances of novel materials. These models will be particularly useful of developing friction materials for other applications than power generating windmills (Ex: heavy-duty industrial applications such as cranes, mining equipment, trains, etc.)********