Synergistic effects of fibre arrangements on the microstructure and properties of organic composite materials

The arrangement of the constituents of organic-composite friction materials is a key factor of their microstructure and thermal and mechanical properties which can influence braking performance. Among these constituents, fibres can present complex morphologies and different arrangements depending on their type and the process of manufacturing. Besides, synergistic effects acting between these constituents and the resulting properties are still not well investigated. This work relates to rock- wool used for brake friction materials, and for which the process can lead to various arrangements. The focus is on synergies between these fibre arrangements and the other material constituents, in ways that reveals the link between the resulting microstructural characteristics and properties of organic composite materials. To achieve these objectives, two simplified formulations are elaborated with two distinct arrangements of rock wool fibres. The friction materials are investigated in terms of microstructure, thermo-physical and mechanical properties. It is found that fibre arrangements affect carbonaceous particle distribution, porosity, and fibre-matrix adhesion. On one side, homogeneous distribution and regular size of fibre bundles results in a better connectedness of conductive particles and thus enhances thermal conductivity. On the other side, a regular fibre bundles repartition lead to a more homogeneous distribution of strain localizations and a softer mechanical response.