Brake Wear Particle Emissions from Dry-Running Friction Systems: Influence of Operating Parameters and Friction Pairing Based on an Application-Oriented Extended Measurement Methodology

Non-exhaust particulate emissions are expected to remain a relevant source of traffic-related air pollution, including an increase in electrified vehicle fleets. Particle formation results from tribological interactions and is influenced by both operating conditions and friction material system. This study presents an extended measurement methodology under application-relevant tribological conditions for the reproducible quantification of PM10 and PM2.5 emissions from dry-running friction systems and applies it to a systematic investigation of operating parameter and friction pairing effects. A dry inertial brake test bench with an enclosed friction chamber and integrated aerosol measurement chain was used under controlled tribologically relevant conditions. Specific friction work and specific friction power were varied by adjusting sliding velocity, contact pressure, and inertial load. Six friction pairings, comprising four representative friction lining types combined with either C45 cast steel or GGG40 gray cast iron, were examined. In situ PM10 and PM2.5 measurements were complemented by gravimetric wear and microstructural analyses. The results show that specific friction work has a direct influence on PM10 and PM2.5 emissions, whereas the independent effect of contact pressure is secondary. Friction power exhibits material-dependent effects. Emissions also vary strongly with friction pairing, indicating that operating conditions and material system must be considered jointly when assessing low-emission brake systems.