Friction materials manufacturing

National Emission Standards for Hazardous Air Pollutants Hydrochloric Acid Production National Emission Standards for Hazardous Air Pollutants for Engine Test Cells/Stands National Emission Standards for Hazardous Air Pollutants for Friction Materials Manufacturing Facilities... 

Table 3 Summary of various tests used in friction material manufacturing for raw material and finished product quality assurance...

About 88% of Hon powder production is used in the manufacture of P/M parts and friction materials. Detailed statistical data are available (16). About 86% of the copper and copper-base powder produced is used in the production of self-lubricating bearings and P/M parts. 

Friction Materials. Sintered friction materials are classified as metal— nonmetal combinations (49,50). These are best manufactured by the P/M process. Clutch plates, brake bands, brake blocks, and packing compositions are examples of friction materials (see Brake linings and clutch facings). 

Processing. Friction materials are manufactured by cold pressing a mixture of the ingredients at relatively low (138—276 MPa (20,000—40,000... 

Biake linings and clutch facings consist of friction materials. Friction materials technology encompasses friction material types, their appHcations, friction and wear characteristics, raw materials, manufacturing methods, and evaluation and test methods. 

Carbon Composites. Cermet friction materials tend to be heavy, thus making the brake system less energy-efficient. Compared with cermets, carbon (or graphite) is a thermally stable material of low density and reasonably high specific heat. A combination of these properties makes carbon attractive as a brake material and several companies are manufacturing carbon fiber—reinforced carbon-matrix composites, which ate used primarily for aircraft brakes and race cats (16). Carbon composites usually consist of three types of carbon carbon in the fibrous form (see Carbon fibers), carbon resulting from the controlled pyrolysis of the resin (usually phenoHc-based), and carbon from chemical vapor deposition (CVD) filling the pores (16). 

Future brakes must satisfy health standards and most vehicle manufacturers have moved toward removing all asbestos from brakes. Lighter weight rotors and caUpers based on aluminum-based metal-matrix materials are also on the horizon for lighter vehicles requiring a whole new family of compatible friction materials. 

Chemical, Physical, and Mechanical Tests. Manufactured friction materials are characterized by various chemical, physical, and mechanical tests in addition to friction and wear testing. The chemical tests include thermogravimetric analysis (tga), differential thermal analysis (dta), pyrolysis gas chromatography (pgc), acetone extraction, liquid chromatography (lc), infrared analysis (ir), and x-ray or scanning electron microscope (sem) analysis. Physical and mechanical tests determine properties such as thermal conductivity, specific heat, tensile or flexural strength, and hardness. Much attention has been placed on noise /vibration characterization. The use of modal analysis and damping measurements has increased (see Noise POLLUTION AND ABATEMENT). 

Berry G, Newhouse ML. 1983. Mortality of workers manufacturing friction materials using asbestos. 

Newhouse ML, Sullivan KR. 1989. A mortality study of workers manufacturing friction materials 1941-86. BrJ Ind Med 46 176-179. 

Different grades of chopped low-carbon steel fibers are used as reinforcements and friction enhancers in formulations. Steel fibers have good reinforcing properties and thermal resistance but high density, poor corrosion resistance, and high thermal conductivity. Chopped stainless steel fibers have found limited application in friction materials and backing layers. Some manufacturers have developed annealed and softer grades of steel fiber to reduce rotor and drum wear. 

Gen] Optical microscopy, friction tests, resistance tests, hardness tests Meehanical and electrieal properties of laser surface remelting/resolidifying proeessed Cr-Cu-Fe contact material manufactured by powder metallurgy... 

Phenolic novolac adhesives are extensively used in Automotive applications bonding friction material to steel in the production of brakes, clutches and drive shafts. They are also used as tyre-cord adhesives and in the manufacture of furniture, laminated board and grinding wheels. See also Wood adhesives - phenolics. 

Because of its application in the manufacturing of porous metaUo-ceramic bearings, of friction materials, parts for machineiy, various alloys, in chemical industry, in manufacture of rechargeable batteries, etc., Fe powder is an important industrial product [55]. Significant amount of Fe powder is produced by electrochemical technique and 20% of electrodeposited Fe powders have to be blended with Fe powders produced by other procedures. The main advantage of electrodeposited Fe powder is its volumetric mass (1.5-2.2 g cm ) and its suitability for pressing, due to dendritic particle shape. 

This company specialises in the manufacture of a wide-range of thermosetting phenolic resins which are tailor made for customers within the following typical industries abrasives (flexible, non-woven and rigids), industrial laminates, refractory, foundry and ancillary products, paper-impregnation, friction materials and general laminating applications. Consequently no data sheets are published. 

Foamed Materials Friction Materials Geosynthetics Granular Materials Hard Materials Heat Resistant Materials Inhomogeneous Materials Laser Materials Magnetic Materials Manufacturing Processes Materials... 

Nylon A class of synthetic fibres and plastics, polyamides. Manufactured by condensation polymerization of ct, oj-aminomonocarboxylic acids or of aliphatic diamines with aliphatic dicarboxylic acids. Also rormed specifically, e.g. from caprolactam. The different Nylons are identified by reference to the carbon numbers of the diacid and diamine (e.g. Nylon 66 is from hexamethylene diamine and adipic acid). Thermoplastic materials with high m.p., insolubility, toughness, impact resistance, low friction. Used in monofilaments, textiles, cables, insulation and in packing materials. U.S. production 1983 11 megatonnes. 

---