Copper leaching from brake wear debris in standard extraction solutions

Quantification of the copper content of and copper leaching from a disc brake wear debris sample was performed using microwave-assisted acid digestion, the Federal Toxicity Characteristic Leaching Procedure (TCLP), and the State of California Waste Extraction Test (WET). The brake wear debris tested was a composite sample obtained from a brake dynamometer test of one brake pad source material. Comparative digestion studies demonstrated that a modified aqua regia matrix (HNO₃ ∶ HCl ∶ H₂O₂ = 1 ∶ 3 ∶ 0.5) optimized the digestion effectiveness for determining the total copper content in the brake wear debris. No significant sample heterogeneity within the brake wear debris was observed, based on statistically indistinguishable total copper content results for subsamples with a wide range of sample masses. Upon pooling all subsample results, an overall total copper content for the composite brake wear debris sample was determined to be 10.8% (g/g), with a 95% confidence limit of ± 0.5% (g/g). Copper leaching increased with decreasing solid-to-liquid ratios in TCLP tests, but was unaffected by the solid-to-liquid ratio in the WET. For a 1 ∶ 10⁴ (g/g) solid-to-liquid ratio, 85% and 99% of the total mass of copper present in the composite brake wear debris sample was leached into solution during the TCLP and WET, respectively. Rate studies also demonstrated that the WET resulted in a faster rate and higher extent of copper leaching relative to the TCLP. Compared to reference copper-containing materials, the composite brake wear debris sample exhibited relatively higher TCLP and WET copper leaching characteristics. The higher copper leaching exhibited by the brake wear debris sample may have resulted from its higher specific surface area and/or from changes in the chemical form of copper that occurred during the braking process.