73

The Application of Bottom Ash Reinforced Aluminum Metal Matrix

Composite for Motorcycle Disc Brake
Maula Nafi1, Muaffaq A. Jani1, Retno Hastijanti1, Ivan A. Parinov2, Shun-hsyung Chang3
1
University of 17 Agustus 1945 Surabaya, Indonesia
2
Southern Federal University, Russia
3
National Kaohsiung Marine University, Taiwan

e-mail: *maula.nafi@untag-sby.ac.id

Metal matrix composite (MMC) by Aluminum matrix and bottom ash reinforce is now developed as a part
of automotive, in this case a motorcycle disc brake. Motorcycle disc brake is fabricated by aluminum
matrix and bottom ash reinforced composite, then given T6 heat treatment. Squeal Noise testing is being
tested afterward with 600, 700, and 800 rpm and weight variation of 3, 4, and 5 kg. The result shows that
composite Al-Bottom Ash has a highest number of sequel noise of 100.7 dB, compared with original
motorcycle disc brake, the sequel noise is 76.8 dB, so that there will be chances of improvements in Al-
Bottom ash composition in fabrication. The variation of 600 rpm and 3kg weight shows the best squeal
noise of 75 dB. Hardness testing with Rockwell F method is done to analyze mechanical properties of the
disc brake. The result shows the hardness of Al-Bottom ash composite is 80.6 HRF, compared to the
original disc brake 59.2 HRF. Overall, composite of Al-Bottom ash has good mechanical and thermal
properties, so that it can be advanced as a spare part of automotive, especially motorcycle disc brake.

Keywords: aluminum matrix, bottom ash reinforced, Al-bottom ash, motorcycle disc brake, hardness
testing, squeal noise

1. Introduction

Disc brakes are one type of brake widely used in modern vehicle braking systems. The
appearance of noise during braking is done like groan, judder, moan and squeal still a problem in
the braking system. Noises emerging due to obstacles to braking system support components
such as discs, brake pads and calipers [1]. One type of sound that is very disturbing is the sound
squeal (sound shrill) which has a frequency above 1000 Hz. This sound comes from an unstable
brake smile today that not only disturbs the calm as well. To avoid the negative effect of
vibration, then in the early stages required vibration shock model that can interfere with the
performance of the brake.
A disc brake has been manufactured by using aluminum matrix composite with
reinforcement of bottom ash coal [2]. Metal matrix composites are combined of two or more
materials, metal is used as a matrix and ceramic is used commonly as the reinforcement.
Aluminum is selected as the matrix because it is lightweight, has good fabrication properties, and
cheap. With the development of composite, aluminum can be combined with ceramics to get
better physical and mechanical properties [3], so that it can be applied as an automotive parts.
T6 heat treatment is commonly used in aluminum alloy fabrication. The purpose of this
heat treatment is to increase the mechanical properties, especially strength and hardness. It
consist of three main steps: solution treatment, quenching, and artificial aging.
 74

This research conducted an experiment of squeal noise testing to a disc brake that
manufactured from Al-Bottom ash composite and T6 heat treatment. The result would be
compared to an original disc brake

1.1. Research Purpose

The objective of this research is to understand the effect of using rpm and weight variation
to the squeal noise of Al-bottom ash disc brake. It also would be a feasibility study of Al-bottom
ash to be applied as automotive parts.

1.2. Research Scope

 The material is Al-bottom ash composite

 Testing conducted are squeal noise and hardness
 Solution treatment: at 540C for 6 hours
 Artificial aging: 180C for 6 hours
 Variation of rpms: 600, 700, and 800 rpms
 Variation of load / weight: 3, 4, and 5 kgs
 Pause between each squeal noise testing : 5 minutes

2. Research Method

Firstly, Al-bottom ash composite is fabricated using the method of stir casting. Aluminum
would be heated until melt in 700oC then it is stirred while insert powder of bottom ash little by
little. The temperature is kept in 700oC and keep stirred until the bottom ash mixed properly in
the molten Al. After that we pour the molten metal in the mold.
Machining process is done to fabricate a disc brake. It used CNC machine. Then T6 heat
treatment is executed in a muffle furnace. Hardness test is conducted to three specimens, original
disc brake, Al-bottom ash disc brake without T6, and Al-bottom ash disc brake after T6. The
hardness testing is using Rockwell F testing because it is purposed for annealed copper alloy,
aluminum alloy, and soft sheet metals [4].
Braking and squeal testing are then executed by a simulation using the model and tools
below.

Sound level meter Thermo laser Digital tachometer

Fig. 1 Tools used to measure squeal noise, rpm, and temperature
 75

Fig. 2 Model to execute squeal noise testing

The squeal noise testing is started by adjusting the speed control for the motor. The
rotation of tire measured by digital tachometer to be accurate to the variation of 600, 700, and
800 rpm. After rotating steadily, load is given to the brake lever so that the braking start until
squealing. Squeal noise is measured by sound level meter. All three specimens are tested the
same way.

3. Result and Discussion

The result of hardness testing can be seen in table 1 below.

Table 1. Hardness testing result

Specimen Hardness (HRF)
Original disc brake 59.2
Al-bottom ash without T6 75.4
Al-bottom ash with T6 80.6

From the hardness result in table 1, basically Al-bottom ash disc brake has higher value of
hardness compared to the original disc brake. There is an escalation of hardness value because of
T6 heat treatment. Al-bottom ash became harder after it was given T6 heat treatment. From this
 76

mechanical properties point of view, we can conclude that Al-bottom ash is feasible to be
alternative for disc brake because it has higher hardness value.
The result of squeal noise testing can be seen in figure 3 below.

Fig. 3 Result of squeal noise testing

From figure 3 we can see that original disc brake has squeal noise of 76.8 dB. From Al-
bottom ash disc brake, the squeal noises are varied based on their variation. The variation of 800
rpm and 3 kg load has the loudest squeal noise, 100.7 dB. The lowest squeal noise is gotten by
variation of 600 rpm and 3 kg load, 75 dB. This result is better than the original disc brake. It
means that by squeal noise testing we can conclude that in specific rpms and loads, Al-bottom
ash composite is feasible to be alternative material for disc brake.
The faster the rotation and the heavier the load, squealing is getting noisier. However in
rotation of 800 rpm, the squealing noise is decreasing in loads of 4 and 5 kg. We can deduct that
there is an optimum number for rotation speed and loads. Therefore, more experiments with more
variation are suggested to be conducted to fill in the gap.

4. Conclusion

From this experiment, we can conclude that

1. There is a difference in hardness between Al-bottom ash and original disc brake. Al-
bottom ash his harder than the original disc brake
2. T6 heat treatment affects the hardness number of Al-bottom ash. Al-bottom ash disc brake
with T6 heat treatment has a higher number of hardness compared to Al-bottom ash
without T6
3. Variation of 300 rpm and 3 kg in squeal noise testing is less noisy than squeal noise in
original disc brake.
4. Al-bottom ash is suitable and feasible composite as an alternative material for disc brake
 77

Acknowledgement

This research was performed into International Conference on Physics and Mechanics of
New Material and Its Application (PHENMA) 2017 in Jabalpur, India.

References

[1] Rusli, M., Okuma, M. 2010. Squeal Noise Analysis in Mechanical Structure with
Friction. VDM Verlag Dr. Mueller e.K.

[2] Seputro, H., Prastio, B., Abdulrahim, M. 2015. The Effect of Electroless Plating on
Aluminum Metal Matrix Composite Reinforcement Bottom Ash on the Density and
Porosity for Propeller Applications. Nova Publisher. Proceeding PHENMA 2015

[3] Ulhas, K., Annigeri, G. B., Kumar, V. 2017. Method of stir casting of Aluminum metal
matrix Composites: A review. Materials Today: Proceeding Vol. 4 No. 2 (1140-1146)

[4] Costa, T. A., Dias, M. Gomes,L. G., Rocha, O. L. Garcia, A. 2016. Effect of Solution
Time in T6 Heat Treatment on Microstructure and Hardness of a Directionally
Solidified Al–Si–Cu Alloy. Journal of Alloy and Compounds Vol. 683 (485-494)

[5] Du, Y., Wang, Y. 2017. Squeal Analysis of a Modal-Parameter-based Rotating Disc
Brake Model. International Journal of Mechanical Sciences Vol. 131-132 (1049-1060)

[6] Aydin, E. 2016. Novel Coal Bottom Ash Waste Composites for Sustainable
Construction. Journal of Construction and Building Materials Vol. 124 (582-588)

[7] Dieter, G. E. 1986. Mechanical Metallurgy 3rd Ed. New York: Mc. Graw-Hill Book Co.