The main objective of this research is to address the relationship between formulation of friction lining materials and their propensity to friction induced noise generation. The basic idea was formulated earlier by Dr. Filip, who showed that the friction layer plays the relevant role when noise is observed during braking. It was shown that when newly formed patches (parts of the friction layer) exhibit a large difference in the coefficient of friction, brake lining is stretched and released repeatedly, which leads to significant vibrations and corresponding noise when coupled with the vibration mode of the system. Farhang ,on the other hand, demonstrated that noise can be related to specific surface roughness parameters and when properties of friction lining and friction layer (such as compressibility, stiffness and modulus of elasticity) fit into certain specific value ranges, noisy behavior occurs. This research will address the braking related to friction induced noise in relation to the properties of the bulk lining material and the character and properties of the friction layer. The friction tests will be performed using the CAFS-developed (Szary and Lee) real time noise measurement system compatible with the major part of SAEJ2521 standard (note that the system does not allow for reliable measurement of frequencies lower than 900 Hz). The mechanical properties of fourteen samples will be investigated. Of the fourteen samples, friction layer of three of the samples will be investigated by several analytical techniques developed by Dr. Filip [1]. They include polarized light microscopy, scanning and transmission electron microscopy equipped with energy dispersive microanalysis, and X-ray diffraction. This research summarizes data from the J2521 dynamometer test of the Dodge Caravan samples exhibiting specific compressibility, porosity and hardness. Also, this research provides the results of friction surface analysis by SEM with energy dispersive microanalysis, light microscopy, surface roughness, and X ray diffraction. Of the fourteen samples, Bendix has the largest occurrence of noisy braking. Based on techniques developed by Dr. Filip, the characteristics of the friction layer strongly influence brake noise propensity. The friction layer characteristics are dependent on brake formulation. As predicted, "noisy stop" and "quiet stop" samples exhibit completely different friction surfaces.

Le rôle des constituants au sein des matériaux de friction pour garniture de frein est encore mal connu du fait, d’une part de la complexité des formulations de ces matériaux composites organiques, d’autre part de la sollicitation induite par le freinage qui engendre de multiples phénomènes physiques. Il s’avère donc particulièrement difficile d’établir les liens entre la composition d’une garniture et ses performances. Les travaux ont concerné une garniture de frein industrielle pour véhicule poids lourd. Une étude préalable a été réalisée du point de vue de sa microstructure et de ses constituants, de ses propriétés, de son élaboration et de ses performances en freinage. La démarche expérimentale adoptée a reposé sur le développement i) d’une formulation « modèle », déduite de la formulation industrielle par simplification de la composition, ii) d’un essai d’usure représentatif de sollicitations de freinage, pour aborder le fonctionnement tribologique des constituants dans une configuration simplifiée. Deux constituants ont été plus particulièrement étudiés, des particules de laiton et des fibres de verre introduites dans la formulation modèle prise en référence. L’analyse des performances a porté sur la compréhension des liens entre les mécanismes de frottement et d’usure, la microstructure et les propriétés des matériaux et leur comportement tribologique / The role of the constituents within friction materials for brake lining still largely unknown due to the complexity of these organic composite formulations and to the induced solicitation by braking which generates multiple physical phenomena. Therefore, it is especially difficult to establish the relationship between the composition of a brake lining and its performance. The work has concerned an industrial brake lining for heavy vehicle. A preliminary study was conducted in terms of its microstructure, constituents, properties, elaboration and its braking performance. The experimental approach was based, on the one hand, on the development of a “model” formulation, derived from the simplification of the industrial one and, on the other hand, on a specific wear test representative of braking solicitations, to take up the tribological behaviour of constituents in the framework of a simplified configuration. Brass particles and glass fibres have been particularly studied, introduced into the model formulation taken as a reference. The analysis of performance has focused on understanding the relationship between friction and wear mechanisms, microstructure and properties of materials, and their tribological behaviour

Les matériaux composites organiques pour garniture de frein à friction sont le fruit d’une élaboration complexe, composée d’une succession d’étapes (mélange de constituants, préformage à froid, moulage à chaud, post-cuisson) ce qui rend difficile la maitrise du lien entre procédé, propriétés et comportement de ces matériaux en particulier du fait des synergies entre les constituants formant le mélange d’une part, et entre la composition et le procédé de fabrication d’autre part. Les travaux de thèse se sont focalisés sur deux étapes de fabrication, le moulage à chaud et la post cuisson, avec l’objectif de mieux comprendre l’influence de certains paramètres du procédé de fabrication sur les performances des matériaux : la température et la durée de moulage à chaud, la durée de post cuisson. L’analyse a porté sur la compréhension des liens entre la microstructure, les propriétés, le comportement tribologique et les mécanismes de frottement et d’usure, par le biais d’une démarche expérimentale fondée sur des formulations matériaux simplifiées ainsi que sur des essais d’usure élémentaires, spécifiques aux sollicitations de freinage / Organic composite friction materials for brake lining result from a complex elaboration made up of successive stages (mixture of constituents, cold preforming, hot molding, post-curing) that makes difficult the mastery of the link between process, properties and behaviour of friction material, especially because of synergies between constituents on one hand, and between composition and manufacturing process on the other hand. Two manufacturing stages were involved in this study, the hot molding and the post-curing, with the aim of a better understanding of the influence of certain parameters of the manufacturing process: the temperature and the duration of hot molding, and the duration of post curing. The analysis has focused on the understanding the relationship between microstructure, properties, tribological behaviour and friction and wear mechanisms of materials.The experimental approach was based on the development of simplified formulations of friction material, and on an elementary wear test specifically designed for braking loadings