Low-Copper Sintered Friction Material for Wear and Heat Resistance
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Solution Overview
Problem
The increasing load on vehicles requires friction materials with excellent wear resistance, heat resistance, and a higher friction coefficient, while reducing copper content to less than 5 mass % to comply with environmental regulations, as copper-based sintered friction materials experience decreased friction coefficient and strength when copper content is reduced.
Innovation Solution
A sintered metal friction material composition with a formulation ratio of 20-40% iron powder, 20-40% nickel powder, 0.5-10% zinc powder, 0.5-5% tin powder, and 0.5-4% copper powder, along with a friction modifier, where iron and nickel powders are the main components, and sintering assist powders like iron boride or phosphor bronze are used to maintain performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If copper powder content is reduced to less than 5 mass %, then environmental compliance is achieved, but friction coefficient and strength decrease
Solution Approach 1:
The invention changes the chemical composition parameters by reducing copper content to less than 5 mass % while adjusting the proportions of iron powder (20-40 mass %), nickel powder (20-40 mass %), zinc powder (0.5-10 mass %), and tin powder (0.5-5 mass %) to maintain material performance. This parameter optimization allows environmental compliance while preserving friction coefficient and strength through balanced composition design
Solution Approach 2:
The invention creates a composite sintered metal friction material combining multiple metal powders (iron, nickel, zinc, tin, and limited copper) with specific proportions. This composite structure leverages the complementary properties of each metal: iron provides base strength, nickel enhances corrosion resistance and strength, zinc improves ductility, and tin contributes to friction characteristics, achieving overall performance without relying on high copper content
2Object-affected harmful factors
If copper powder content is reduced to less than 5 mass %, then environmental compliance is achieved, but wear resistance decreases
Solution Approach 1:
The invention optimizes composition parameters by limiting copper to less than 5 mass % while precisely controlling the ratios of iron powder (20-40 mass %), nickel powder (20-40 mass %), zinc powder (0.5-10 mass %), and tin powder (0.5-5 mass %). This parameter adjustment maintains wear resistance through the synergistic effect of the multi-metal composite structure, where nickel and zinc contribute to surface hardness and durability
Solution Approach 2:
The invention develops a composite material system where iron, nickel, zinc, and tin powders work together to provide wear resistance. The sintering process creates a dense microstructure with strong intermetallic bonds, and the friction modifier components further enhance surface properties, ensuring reliable wear performance without depending on high copper content
3Object-affected harmful factors
If copper powder content is reduced to less than 5 mass %, then environmental compliance is achieved, but heat resistance at high load decreases
Solution Approach 1:
The invention adjusts composition parameters by reducing copper to less than 5 mass % while optimizing iron powder (20-40 mass %) and nickel powder (20-40 mass %) content. This parameter change maintains heat resistance at high load through the high melting point and thermal stability of the iron-nickel base matrix, which can withstand severe thermal conditions without degrading
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 with reduced copper content, maintaining performance even under repeated use and high loads, while adhering to environmental standards.
Implementation Method 1
a sintered body obtained by sintering a matrix metal and a filler component
Data Source
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.