Development Brake Development of Suitable Calcined Refractory Clay for Automobile Brake Pads

Abstract

Alumino-silicate fireclay material was found within the equatorial region of Ekiti state of Nigeria. From Ijero-Ekiti, fireclay samples were explored, exploited and developed into automobile brake pads. Eight samples were taken from 5 to 30 metres downward at various pits to prevent unwanted foreign materials. Specifically, these samples were examined and found to be characteristically homogeneous in physical, mechanical, mineralogical and chemical composition. 30 per cent of the unwanted foreign materials from the fireclay were technically removed with above 45 micron  sieve using a wet sieving method. 70 per cent of the purified clay of less than 45 micron sieve was eventually used as beneficiated fireclay material. After the purification, sample clay obtained was finally calcined at 1500⁰C temperature for clay structural stability and prevention of excessive clay shrinkage. The refractory clay material was eventually made into various is batches using a mathematical model. Material composition fomula used was technically based on range of grain particle sizes (30  to 70 per cent) grog or calcined clay; and beneficiated clay range of particle sizes of 70 to 30 per cent as the binding agent respectively. Thereafter, batch material compositions were homogeneously mixed and properly wedge together in a pugged mill before they were hydraulically pressed with 1000kg/mm² with a designed steel mould. Automobile brake pads made were characteristically tested and found suitable for light (Cars) vehicles usage 80 per cent efficiency.