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<p>A critical challenge remains for non-asbestos organic (NAO) brake composites reinforced with hard ceramic ZrSiO₄ microparticles, which act as the primary load-bearing phase to effectively enhance wear resistance yet inevitably induce severe scratching damage to the steel counterface. To resolve this conflict between wear protection and surface damage, this paper systematically introduced ZrO₂ nanoparticles into ZrSiO₄-containing NAO composites and investigated their influence on tribological behavior and tribofilm evolution under varying sliding speeds and contact pressures. The results revealed an obvious dual mechanism between ZrSiO₄ microparticles and ZrO₂ nanoparticles. ZrSiO₄ microparticles support the external load and promote intense tribo-oxidation that forms a protective iron-oxide layer at elevated speeds, yet their aggressive plowing action continuously scores the steel surface. Conversely, ZrO₂ nanoparticles can effectively remove pre-existing oxide layers on the steel surface and promote tribo-sintering of wear debris into a compact, continuous tribofilm, that effectively passivates the counterface and suppresses scratching. However, this protective sintered tribofilm is repeatedly torn and dislodged by hard ZrSiO₄ particles, resulting in continuous tribofilm regeneration that significantly raises the specific wear rate of the composite and introduces pronounced friction instability during the running-in stage. The synergy between ZrSiO₄ and ZrO₂ thus dictates a fundamental trade-off: nanoparticle-enabled counterface protection is obtained at the expense of moderately sacrificed composite wear resistance. These findings clarify the micro-nano synergistic tribological mechanism and provide a mechanistic basis for designing next-generation brake materials that balance counterface friendliness with overall tribological performance.</p>

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Influence of ZrO₂ nanoparticle incorporation in brake composites on tribofilm evolution and tribological mechanisms on the steel counterface

  • 期刊论文

  • 发表日期：

    2026年6月22日

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  • Qinglun Che,
  • Zhenhang Yang,
  • Ruao Dong,
  • Kewei Li,
  • Jinhong Chen,
  • Jianjun Zhang,
  • Shaomei Zheng,
  • Guoxiang Hao,
  • Huifa Shi,
  • Jingjing Zhang

摘要

A critical challenge remains for non-asbestos organic (NAO) brake composites reinforced with hard ceramic ZrSiO₄ microparticles, which act as the primary load-bearing phase to effectively enhance wear resistance yet inevitably induce severe scratching damage to the steel counterface. To resolve this conflict between wear protection and surface damage, this paper systematically introduced ZrO₂ nanoparticles into ZrSiO₄-containing NAO composites and investigated their influence on tribological behavior and tribofilm evolution under varying sliding speeds and contact pressures. The results revealed an obvious dual mechanism between ZrSiO₄ microparticles and ZrO₂ nanoparticles. ZrSiO₄ microparticles support the external load and promote intense tribo-oxidation that forms a protective iron-oxide layer at elevated speeds, yet their aggressive plowing action continuously scores the steel surface. Conversely, ZrO₂ nanoparticles can effectively remove pre-existing oxide layers on the steel surface and promote tribo-sintering of wear debris into a compact, continuous tribofilm, that effectively passivates the counterface and suppresses scratching. However, this protective sintered tribofilm is repeatedly torn and dislodged by hard ZrSiO₄ particles, resulting in continuous tribofilm regeneration that significantly raises the specific wear rate of the composite and introduces pronounced friction instability during the running-in stage. The synergy between ZrSiO₄ and ZrO₂ thus dictates a fundamental trade-off: nanoparticle-enabled counterface protection is obtained at the expense of moderately sacrificed composite wear resistance. These findings clarify the micro-nano synergistic tribological mechanism and provide a mechanistic basis for designing next-generation brake materials that balance counterface friendliness with overall tribological performance.