The Role of Copper on the Friction and Wear Performance of Automotive Brake Friction Materials - PowerPoint PPT Presentation

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The Role of Copper on the Friction and Wear Performance of Automotive Brake Friction Materials

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The Role of Copper on the Friction and Wear Performance of Automotive Brake Friction Materials S.H. Sung*, J.J. Lee, J.H. Cha, J.H. Jo Sangsin Brake Corporation – PowerPoint PPT presentation

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Title: The Role of Copper on the Friction and Wear Performance of Automotive Brake Friction Materials


1
  • The Role of Copper on the Friction and Wear
    Performance of Automotive Brake Friction Materials

S.H. Sung, J.J. Lee, J.H. Cha, J.H. Jo Sangsin
Brake Corporation S.J. Kim, J.Y. Lee, J.M. Han,
Y.C. Kim, H.D. Park Hyundai Motor Company H.
Jang Korea University
2
Background
  • Coppers feature

Copper fiber
  • High Ductility
  • High Thermal Conductivity
  • Proper Melting Point
  • Low Mohs Hardness

Copper powder
? Play a role as a solid lubricant for high
temperature
3
Objective
Investigate the role of cuprous ingredients in
friction materials
The copper is an essential component in friction
materials
The contamination of storm water and bay from
brake pad wear debris
The limitation to the use of copper Current
regulation in the United States
Development of Cu reduction Cu-free friction
material
4
Current Regulation of Copper
2020 New York 5wt ?
Not yet decided New York Washington Rhode
Island Oregon 0.5wt ?
2021 Washington California Rhode
Island Oregon 5wt ?
2025 California 0.5wt ?
5
Cuprous Ingredients
Copper Sulfide (CuS)
Cupric Oxide (CuO)
Copper fiber
Copper Powder
8.9
8.2
6.6
4.5
Density (g/?)
6
Non-steel Formulation
Raw materials wt. Raw materials wt. Cu-free CuF CuP CuO CuS CuF3 CuF5 CuF10 CuO3 CuO5 CuO10
Cuprous ingredients Copper fiber Copper powder Cupric oxide Copper sulfide 0 0 0 0 10 0 0 0 0 10 0 0 0 0 4 0 0 0 0 4 3 0 0 0 5 0 0 0 10 0 0 0 0 0 3 0 0 0 5 0 0 0 10 0
Binder Binder 8 8 8 8 8 8 8 8 8 8 8
Reinforcement Reinforcement 15 15 15 15 15 15 15 15 15 15 15
Friction modifier Friction modifier 55 55 55 55 55 55 55 55 55 55 55
Space filler Space filler 22 1218 1218 1218 1218 1219 1219 1219 1219 1219 1219
7
Brake Performance Wear Test
Performance test Wear test



1/5 scale dynamometer
Full scale dynamometer
- Standard burnish - Braking temperature range
100400
- JASO C406-P1 Mode
8
Wear Test Procedure
Section Initial velocity (kph) Braking temp (?) Decele ration (G) Braking applications
Burnish 80 100 0.3 250
Wear test 50 50 50 50 60 60 65 100 150 200 250 300 350 400 0.3 0.3 0.3 0.3 0.3 0.3 0.3 250 250 250 250 250 250 250
9
Physical Properties (Effect of the type)
Copper fiber
10
Physical Properties (Effect of the amount)
11
Friction Coeff. Disk Wear
Copper free
CuS
12
The Change of Friction Coeff. (as a function of
deceleration)
2nd effectiveness _at_ 130kph
0.46
Cu fiber
CuS
Cu free
0.30
13
The Change of Friction Coeff. (with different
amounts of copper fiber)
50kph
100kph
130kph
100kph
Fade
Effectiveness
14
The Change of Friction Coeff. (with different
amounts of cupric oxide)
50kph
100kph
130kph
100kph
Fade
Effectiveness
15
The Change of Friction Material Wear (with
different amounts of copper fiber)
Copper fiber 10wt
Copper fiber 5wt
Copper fiber 3wt
Copper free
16
The Change of Friction Material Wear (with
different amounts of cupric oxide)
Cupric oxide 10wt
Cupric oxide 3wt
Cupric oxide 5wt
Copper free
17
Worn Surface Morphology



Cu free
Copper Fiber 10 wt.
Cupric Oxide 10 wt.
18
The Change of Friction Coeff. _at_ 350? (with
different amounts of copper fiber)
Copper fiber 10wt
Copper free
19
The Change of Friction Coeff. _at_ 350? (with
different amounts of cupric oxide)
Cupric oxide 10wt
Copper free
20
Summary
1. Physical property 1) The type and
amount of cuprous ingredients showed little
effect on the hardness and
compressibility 2) Copper fiber showed
better thermal conductivity 2. Performance test
by the type of cuprous ingredients 1)
Copper fiber, powder, oxide showed a mild
aggressiveness compare with copper
free and sulfide 2) Copper fiber and
sulfide improved the friction stability,
copper free showed reduction of µ and severe
disk wear
21
Summary
3. Performance test with different amounts of
copper fiber or oxide 1) Copper fiber
amount increases, friction coefficient was
increased on the contrary, the
friction coefficient was decreased with cupric
oxide 2) The friction material containing
10 wt. of cupric oxide showed
improved fade resistance 4. Wear test with
different amounts of copper fiber or oxide
1) Copper fiber showed better wear resistance
than cupric oxide 2) While increasing the
copper fiber amount, total wear increased
3) Cuprous ingredients played an important role
in improving friction stability at
elevated temperatures
22
Thank you for your attention
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