Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure

Talha İkbal Çığır; Melih Hakan Samur; Mevlüt Yasin Igdeli

doi:10.30939/ijastech..1811564

Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure

Abstract

This study compares the friction performance of three commonly used cast brake disc materials in the automotive industry: the G3000 variant, GG20, and GG15 (high carbon content). Samples were tested on an inertia dynamometer following the SAE J2522 AK Master procedure, using the same type and batch of brake pads. In addition to performance tests, the structural and chemical properties of the materials were analyzed. Microstructural examinations evaluated lamellar graphite morphology, pearlite-ferrite ratio, and graphite size, while chemical analyses showed that the GG15 sample has a carbon content exceeding standard ranges. Structural and chemical properties of the materials were also analyzed alongside performance tests. Chemical compositions were confirmed via spectrometry, revealing that the carbon content of the GG15 sample (%3.72) exceeds standard ranges and is classified as “high carbon” by the manufacturer. The term “G3000 variant” in this study refers to a material that does not exactly replicate the mechanical properties of the original G3000 but represents a variant with some improved characteristics. Results indicated that the materials exhibited similar average friction coefficients. Differences in microstructure and thermal conductivity were observed to influence friction behavior in certain segments. These findings provide valuable engineering inputs for material selection and design.

Keywords

Supporting Institution

AYD Automotive Industry Inc.

Thanks

I would like to express my gratitude to Mr. Harun Aydın, Chairman of the Board of Directors, Mr. Halil Aydın, CEO, and Mr. Mehmet Fatih Aydın, Brake Disc Factory Director, for their contributions to the implementation of this project. I would also like to extend my sincere gratitude to all my team members who contributed to the project process for their contributions and dedicated work. I would also like to thank the AYD Automotive Industry family for their support and resources, which made this project possible.

References

[1] Limpert R. Brake Design and Safety. 2nd ed. Warrendale (PA): SAE International; 1999.
[2] Blau PJ. Compositions, Functions, and Testing of Friction Brake Materials and Their Additives. Oak Ridge (TN): Oak Ridge National Laboratory; 2001. Report No. ORNL/TM 2001/64.
[3] Bijwe J. Composites as friction materials: Recent developments in non asbestos fiber reinforced friction materials – A review. Polym Compos.1997;18(3):378–396.
[4] Cueva G, Sinatora A, Guesser WL, Tschiptschin AP. Wear resistance of cast irons used in brake disc rotors. Wear. 2003;255:1256–1260.
[5] Eriksson M, Bergman F, Jacobson U. On the nature of tribolog-ical contact in automotive brakes. Wear. 2002;252:26–36.
[6] Talati E, Jalalifar A. Analysis of heat conduction in a disc brake system. Heat Mass Transfer. 2009;45:1047–1059.
[7] Kukutschová S, et al. On airborne nano/micro sized wear parti-cles released from low metallic automotive brakes. Environ Pol-lut. 2011;159(4):998-1006.
[8] Mutlu A, Aydın N. The effect of graphite shape and matrix structure on wear behaviour of cast iron brake discs. Mater Test. 2014;56(5–6):422–428.

[9] Blau J. Friction Science and Technology: From Concepts to Applications. 2nd ed. Boca Raton: CRC Press; 2008.
[10] Al Saba T, Hasan F. Effect of heat treatment on the mechanical properties of grey cast iron used in brake discs. Mater Today Proc. 2020;26:3051–3056.
[11] Radhakrishnan R, Iyer S, Natarajan V. Thermal fatigue behavior of gray cast iron brake discs: Finite element modeling and exper-imental validation. Int J Therm Sci. 2016;109:124–132.
[12] Song K, Choi J. Experimental study on cooling performance of ventilated brake discs with different vane configurations. Appl Therm Eng. 2018;145:423–432.
[13] Lee D, Moon Y. Microstructural evaluation of crack propaga-tion in grey cast iron brake discs. Eng Fail Anal. 2019;96:150–160.
[14] Cho MH, Lee KH, Kim HJ. Influence of casting and machining processes on tribological characteristics of brake discs. Tribol Int. 2013;60:277–285.
[15] Çığır, T. İ., Eser, A. A., Göğer, F., & Acarer, M. (2024). Com-parison of Surface Hardening Processes Applied to AISI 5140 Steel with Side Load Test. International Journal of Automotive Science and Technology, 8(1), 87–95.
[16] Ketenci N., Duran A. (2024). A Systematic Review of Brake Pad. International Journal of Automotive Science and Techno-logy, 8(4), 404–418.
[17] Şeker U, Köklü U. Farklı mikroyapıya sahip gri dökme demirle-rin mekanik ve tribolojik özellikleri. Gazi Univ Müh Mim Mim Fak Derg. 2005;20(4):543–550.
[18] International Organization for Standardization. ISO 185:2005. Grey cast irons – Classification. Geneva: ISO; 2005.
[19] Tekkaya E, Niemeyer M, Jäckel A. Thermal and mechanical properties of cast iron materials used in brake discs. J Mater Process Tech. 2010;210:1029–1036.
[20] Gopal J, Venkataswamy R. Effect of graphite morphology and matrix microstructure on the wear behavior of cast iron brake ro-tors. Wear. 2011;271:2386–2393.
[21] Rhee SK, Tsang PHS. Laboratory friction testing of automotive brake materials. Tribol Trans. 1998;41(4):653–659.
[22] Hohmann C. Development of a full scale inertia brake dynamo-meter and procedures for fade and wear testing of automotive disc brakes. SAE Tech Pap. 2000; Paper No. 2000 01 2756.
[23] Setiyo M, Waluyo B. Mixer with Secondary Venturi: An Inven-tion for the First-Generation LPG Kits. Int J Automot Sci Tech-nol. 2019;3(1):21–26.
[24] Can Ö, Öztürk E, Solmaz H, Aksoy F, Çinar C, Yücesu HS. Combined effects of soybean biodiesel fuel addition and EGR application on the combustion and exhaust emissions in a diesel engine. Appl Therm Eng. 2016;95:115–124.

Details

Primary Language

English

Subjects

Materials Engineering (Other), Vehicle Technique and Dynamics, Automotive Engineering (Other)

Journal Section

Research Article

Authors

Talha İkbal Çığır ^*
0009-0007-4509-4484
Türkiye

Melih Hakan Samur
0009-0005-6184-202X
Türkiye

Mevlüt Yasin Igdeli
0009-0000-2766-7882
Türkiye

Early Pub Date

December 16, 2025

Publication Date

December 31, 2025

Submission Date

October 27, 2025

Acceptance Date

December 5, 2025

Published in Issue

Year 2025 Volume: 9 Number: 4

DOI

https://doi.org/10.30939/ijastech..1811564

IZ

https://izlik.org/JA86WN79JW

Cite

RIS / Bibtex

APA

Çığır, T. İ., Samur, M. H., & Igdeli, M. Y. (2025). Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure. International Journal of Automotive Science And Technology, 9(4), 500-516. https://doi.org/10.30939/ijastech..1811564

AMA

1.Çığır Tİ, Samur MH, Igdeli MY. Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure. IJASTECH. 2025;9(4):500-516. doi:10.30939/ijastech.1811564

Chicago

Çığır, Talha İkbal, Melih Hakan Samur, and Mevlüt Yasin Igdeli. 2025. “Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure”. International Journal of Automotive Science And Technology 9 (4): 500-516. https://doi.org/10.30939/ijastech. 1811564.

EndNote

Çığır Tİ, Samur MH, Igdeli MY (December 1, 2025) Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure. International Journal of Automotive Science And Technology 9 4 500–516.

IEEE

[1]T. İ. Çığır, M. H. Samur, and M. Y. Igdeli, “Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure”, IJASTECH, vol. 9, no. 4, pp. 500–516, Dec. 2025, doi: 10.30939/ijastech..1811564.

ISNAD

Çığır, Talha İkbal - Samur, Melih Hakan - Igdeli, Mevlüt Yasin. “Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure”. International Journal of Automotive Science And Technology 9/4 (December 1, 2025): 500-516. https://doi.org/10.30939/ijastech. 1811564.

JAMA

1.Çığır Tİ, Samur MH, Igdeli MY. Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure. IJASTECH. 2025;9:500–516.

MLA

Çığır, Talha İkbal, et al. “Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure”. International Journal of Automotive Science And Technology, vol. 9, no. 4, Dec. 2025, pp. 500-16, doi:10.30939/ijastech. 1811564.

Vancouver

1.Talha İkbal Çığır, Melih Hakan Samur, Mevlüt Yasin Igdeli. Investigation of the Friction Performance of G3000 (Variant), GG20, and GG15 (High Carbon) Cast Brake Discs Using the SAE J2522 Procedure. IJASTECH. 2025 Dec. 1;9(4):500-16. doi:10.30939/ijastech. 1811564