Calculation and experimental study in the braking temperature of aluminum-based and cast steel brake discs

Purpose This study aims to analyze the temperature difference between aluminum-based brake disc (ABD) and cast steel brake disc (CSBD) for rail vehicles in the braking process, which is related to the popularization and use of ABD. Design/methodology/approach Two friction pairs composed of ABD, CSBD and copper-based powder metallurgy brake pad were studied in this paper. The temperature characteristics of the two friction pairs were compared by 1:1 braking test and simulation calculation. Findings When the speed is 160–250 km/h and the braking pressure is 18 and 29 kN, the calculated maximum temperature of CSBD is 574°C and 681°C, respectively, which is higher than that of ABD 49°C–148°C and 73°C–217°C. Under the test conditions, the maximum temperature of CSBD is 487°C and 624°C respectively, which is higher than that of ABD 63°C–95°C and 63°C–188°C. The temperature difference between ABD and CSBD increases with the increase of braking pressure and speed. The surface temperature distribution of CSBD is “three-peak,” whereas that of ABD is “single-peak.” Originality/value This paper reveals the temperature difference between ABD and CSBD and provides data support for promoting the use of ABD. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2024-70320/