Sintered Friction Material Composition for Low-Copper Brake Performance
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Solution Overview
Problem
The increasing load and speed of vehicles require friction materials with excellent wear resistance, heat resistance, and a higher friction coefficient, while reducing copper content to less than 5 mass% due to environmental restrictions, without compromising performance over repeated use.
Innovation Solution
A sintered metal friction material composition with a formulation of 20-40% iron powder, 20-40% nickel powder, 0.5-10% zinc powder, 0.5-5% tin powder, and 0.5-5% copper powder, along with a friction modifier, where the nickel and iron powders are key components, and the copper content is minimized to meet environmental standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper powder is used as a main component of matrix metals to achieve excellent wear resistance, heat resistance and high friction coefficient, then the friction material performance is improved, but the copper content exceeds the environmental restriction limit of 5 mass%
Solution Approach 1:
The patent changes the chemical composition parameters of the matrix metals by reducing copper content from 30-37 mass% to less than 5 mass%, while adjusting iron powder (20-40 mass%), nickel powder (20-40 mass%), zinc powder (0.5-10 mass%), and tin powder (0.5-5 mass%) to achieve the required wear resistance and friction properties without exceeding environmental limits
Solution Approach 2:
The patent creates a composite matrix metal system combining iron powder, nickel powder, zinc powder, tin powder, and minimal copper powder with sintering assist powder, where the synergistic interaction of these components achieves excellent wear resistance, heat resistance, and friction coefficient while maintaining copper content below 5 mass%
2Object-affected harmful factors
If copper powder content is reduced to meet environmental restrictions, then environmental protection is improved, but wear resistance, heat resistance and friction coefficient decrease
Solution Approach 1:
The patent adjusts the formulation parameters by incorporating sintering assist powder (0.5-5 mass%) comprising iron boride powder, iron phosphide powder, copper phosphide powder, or phosphor bronze powder, which enhances sintering efficiency and matrix metal bonding, thereby maintaining heat resistance and wear resistance even with reduced copper content
Solution Approach 2:
The sintering assist powder acts as an intermediary that facilitates the sintering process and strengthens the matrix metal structure, compensating for the reduced copper content by improving the bonding between iron, nickel, zinc, and tin particles, thus preserving heat resistance and mechanical properties
3Object-affected harmful factors
If copper powder content is reduced to meet environmental restrictions, then environmental protection is improved, but friction coefficient decreases
Solution Approach 1:
The patent optimizes the friction material composition by adjusting the ratios of iron powder, nickel powder, zinc powder, and tin powder, and incorporating sintering assist powder that enhances the friction properties of the matrix, thereby maintaining a high friction coefficient even with copper content reduced to less than 5 mass%
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The material achieves excellent wear resistance, heat resistance, and a higher friction coefficient, maintaining performance without significant decrease, even at high loads, while reducing copper content to less than 5 mass%, and exhibits suitable fade resistance and torque stability.
Implementation Method 1
a sintered body obtained by sintering a matrix metal and a filler component
Data Source
Figure 1~2
AI summary
The present invention provides a sintered metal friction material that has excellent wear resistance, heat resistance even at high load and has a higher friction coefficient while maintaining a friction coefficient and wear resistance that are hard to decrease, and has a reduced content of copper of less than 5 mass%. There is provided a sintered metal friction material characterized in that the sintered metal friction material comprises a sintered material of a friction material composition, the friction material composition comprises matrix metals and a friction modifier, the matrix metals comprise following 20 to 40 mass% of iron powder, 20 to 40 mass% of nickel powder, 0.5 to 10 mass% of zinc powder, 0.5 to 5 mass% of tin powder, 0.5 to 4 mass% of copper powder and 0.5 to 5 mass% of sintering assist powder.