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Keeping recycling and the circular economy in mind, this study explores the reduction in emission of a highly optimized, commercially employed friction material formulation through the addition of metallurgical slags from a basic oxygen furnace in varying quantities from 6 to 38 wt%. The various compositions were paired with a pearlitic grey cast iron counterface and tested on a pin on disc tribometer. The friction coefficient and pin wear increased with the slag addition but were still within the permissible limit when compared to the original formulation. Specimens with higher slag content observed extremely compacted and extended secondary contact plateaus, which also recorded significant slag presence. The extended plateaus detached in the form of chunks from the mating surfaces, which settled on the equipment hardware and restricted the production of airborne particles. From an industrial symbiosis perspective, the addition of metallurgical slags proved to be a promising way of obtaining green friction materials with reduced emissions.

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The need to reduce non-exhaust particulate matter emissions is of paramount importance as they pose repercussions on human lives and the environment. In this study, a novel way to limit emissions is proposed based on the minimization of the vibration of the mating bodies. Two model friction material formulations were tested in the form of pins and paired with a pearlitic grey cast iron disc counterface in a laboratory pin on disc apparatus. To reduce the vibrations, a damping tape was wrapped around the pins. With the damping of vibration, a significant drop in the emissions was recorded, and this was correlated with the friction layer establishment during sliding, which observed low disruption. It is believed that the use of this method for reducing emissions can accompany the optimization phase of the brake squeal noise of friction materials, thereby, providing new design perspectives.

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A new methodology has been developed to prepare electron microscopy, both SEM and TEM, specimens starting from particulate matter collected using environmental sampling systems. The approach is based on the extraction of the particles to be analyzed from the harvesting substrates. The extracted particles can be directly observed in an SEM, possibly in low-vacuum mode to prevent electrical charging. In order to prepare electron transparent samples, TEM observations require a further step, consisting in embedding the particles in an electron transparent carbon film deposited before dissolving the acetate extracting substrate. The protocol has been tested by analyzing particles collected during bench tests on brake pads and discs, carried out on a dynamometer equipped with a particulate matter sampling apparatus. The main advantages of the approach are: the complete extraction of the particulate matter specimens from the original substrates, that in this way do not interfere with the analyses; the extracted samples retain the topological information of the collection in the specimens prepared for SEM; possibility to be applied to any kind of particulate matter harvesting substrates.

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This critical review presents several aspects related to the use of copper as a main component in brake pads in road vehicles. The compositions of these materials are attracting increasing interest and concern due to the relative contribution of wear products to particulate matter emissions in the environment as a result of braking action even though there has been a reduction in exhaust products from internal combustion engines. We review the data on the main wear mechanisms in brake systems and highlight the positive role of copper. However, similar to other heavy metal emissions, even the release of copper into the atmosphere may have important environmental and health effects. Thus, several replacement strategies are being pursued, and the positive and negative features will be critically reviewed. Additionally, the future perspectives in materials development will be discussed.

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