Application of Chalcopyrite Powder in Brake Shoes Production
In the realm of brake shoes manufacturing, Chalcopyrite Powder has emerged as a material with distinct characteristics that impact the performance of brake shoes friction materials. Incorporated into brake shoes mixtures and mixes, it brings both advantages and disadvantages to the table, which are closely related to its technical parameters.
Technical Parameters
- Friction Coefficient Contribution: When added to brake shoes friction materials, chalcopyrite powder can influence the friction coefficient. In laboratory – tested brake shoes mixes with a 10% chalcopyrite powder content, the average friction coefficient under normal braking conditions (at a speed of 60 km/h and a braking force of 500 N) was measured to be around 0.4 – 0.45. This value indicates its ability to contribute to the braking force generation.
- Wear Resistance Factor: Chalcopyrite powder has a certain level of hardness and structure that affects the wear resistance of the brake shoes. Micro – structural analysis shows that in a brake shoes mixture, the presence of chalcopyrite powder can reduce the wear rate of the friction material. For every 5% increase in chalcopyrite powder content, the wear rate was observed to decrease by approximately 8% during a 50 – hour continuous braking simulation test.
- Thermal Stability: Chalcopyrite powder can maintain its structural integrity up to a certain temperature. It starts to decompose at around 500 – 550°C. This thermal stability is crucial as during braking, the temperature of the brake shoes can rise significantly. In high – speed braking scenarios where the temperature of the brake shoes can reach up to 400°C, chalcopyrite powder – containing brake shoes can still maintain their mechanical and frictional properties relatively well.
Advantages
- Improved Braking Performance: The addition of chalcopyrite powder can enhance the braking performance of brake shoes. In real – world driving tests on a vehicle with a mass of 1500 kg, the braking distance was reduced by about 10% when using brake shoes with a 15% chalcopyrite powder content compared to those without it. This improvement is mainly due to its ability to provide a stable and appropriate friction coefficient during braking.
- Cost – effective Friction Modulation: Compared to some high – end friction – enhancing materials like certain synthetic polymers, chalcopyrite powder offers a cost – effective way to modulate the friction in brake shoes. The cost of chalcopyrite powder is approximately 30 – 50% lower than these high – end materials per unit mass, making it an attractive option for brake shoe manufacturers aiming to balance performance and cost.
- Enhanced Durability: As mentioned earlier, the wear – resistance property of chalcopyrite powder contributes to the enhanced durability of brake shoes. Field – test results show that brake shoes with chalcopyrite powder can last 20 – 30% longer than traditional brake shoes in normal urban driving conditions, which involve frequent braking and acceleration.
Disadvantages
- Corrosion Potential: Chalcopyrite powder contains sulfur, which can lead to corrosion issues in the presence of moisture and oxygen. In a humid environment with a relative humidity of over 70%, brake shoes with chalcopyrite powder showed signs of surface corrosion within 3 months. This corrosion can not only damage the appearance of the brake shoes but also affect their mechanical and frictional properties over time.
- Limited High – Temperature Performance: Although chalcopyrite powder has a certain thermal stability, at extremely high temperatures (above 550°C), its performance degrades rapidly. In racing – type braking situations where the temperature of the brake shoes can exceed 600°C, the friction coefficient of brake shoes with chalcopyrite powder can drop by up to 40%, leading to significant brake fade.
- Environmental Impact: The extraction and processing of chalcopyrite powder have environmental implications. Mining chalcopyrite can cause land – use changes and may release heavy metals into the environment if not properly managed. Moreover, the sulfur – containing compounds in the powder can contribute to air pollution when the brake shoes wear and release particles during use.
In summary, while chalcopyrite powder offers notable advantages in improving braking performance, cost – effectiveness, and durability in brake shoes production, its disadvantages in terms of corrosion potential, high – temperature performance limitations, and environmental impact must be carefully considered. Brake shoe manufacturers need to conduct comprehensive evaluations based on their specific product requirements and market demands.