Design and regulation of 3D mesh structure inside Cu-based friction materials and the tribological behaviors

The poor friction coefficient (COF) stability and overlarge abrasion have become the bottleneck problem of Cu-based friction materials (CBFMs). At present, the structure optimization of CBFMs were neglected. This paper proposed a new method of constructing and regulating 3D mesh structure inside CBFMs. The samples were prepared by step mixing, wet granulation, particle coating, pressing and sintering. The structure activity relationship between 3D mesh structure and comprehensive properties were investigated; the force-thermal dynamic multifield characteristics were investigated by Finite Element Method. The results showed that 3D mesh structure inside CBFMs could quickly conduct the friction heat outside, which could alleviate COF heat fade and abnormal abrasion. Sample holding 3D mesh structure had a greatly enhancement in heat conductivity and a great improvement in mechanical properties of 61.5%, which could enhance the comprehensive tribological properties. Sample holding 3D mesh structure got a reduced wear rate of 50.17%. This study can provide a new idea for the design and fabrication of structured friction materials, and lay a theoretical foundation for the further study of CBFMs.