Various kinds of friction materials were manufactured by adding 10%, 20%, and 30% of reduced iron, respectively, which has been obtained during the reduction process of blast furnace sludge extracted from the blast furnace, and its iron oxide, instead of existing barium sulfate(BaSO4) among the components of automobile brake friction materials. Fundamental physical property test and friction performance test, etc., using a brake dynamometer were carried out against these friction materials. Furthermore, when the expensive filling material, BaSO4 was substituted by reduced iron and added to the friction material, the added content of reduced iron for an excellent friction characteristic considering the heat emission temperature, wear, etc., was 10%. In the fundamental physical property test, as the added content of blast furnace sludge or reduced iron increased, and as the content increased, the shear strength and bonding strength of friction materials decreased, but both of them indicated sufficient strengths to be applied to a friction material. Even in the frictional performance test using a brake dynamometer, as the added content of blast furnace sludge or reduced iron increased, the friction coefficient reacted insensibly to brake deceleration, and its stability was improved.

The friction characteristics of Al-Fe alloy powders are investigated in order to develop an eco-friendly friction material to replace Cu fiber, a constituent of brake-pad friction materials. Irregularly shaped Al-Fe alloy powders, prepared by gas atomization, are more uniformly dispersed than conventional Cu fiber on the brake pad matrix. The wear rate of the friction material using Al-8Fe alloy powder is lower than that of the Cu fiber material. The change in friction coefficient according to the friction lap times is 7.2% for the Cu fiber, but within 3.8% for the Al- Fe alloy material, which also shows excellent judder characteristics. The Al-Fe alloy powders are uniformly distributed in the brake pad matrix and oxide films of Al and Fe are homogeneously formed at the friction interface between the disc and pad, thus exhibiting excellent friction and lubrication characteristics. The brake pad containing Al-Fe powders avoids contamination by Cu dust, which is generated during braking, by replacing the Cu fiber while maintaining the friction and lubrication performance.

신제품 개발에 있어서 제품의 잠재적 고장모드를 줄이기 위한 설계 노력은 매우 중요하며 이를 위해서는 체계적이고 혁신적인 신뢰성프로그램을 적용하는 것이 반드시 필요하다. 기업에서 동시공학을 기초로 한 건전한 신뢰성프로그램에 포함된 주요활동으로는 DFR(Design for Reliability), 신뢰성검증 및 물리적 해석활동 등이 있으며, 이 중 DFR은 제품 개발을 지원하는 첫 번째 과학적 신뢰성활동이다. 본 연구는 브레이크패드의 신뢰성을 향상시키기 위

In spite of unparalleled combination of essential material properties for brake linings and clutch facings, replacement for asbestos is seriously called for since it is a health hazard. Once asbestos is replaced with other material then composition and properties of brake pad changes. In certain cases hardness of the material may be high enough to affect the rotor material. In this study, hardness of the brake pad has been controlled using suitable reinforcement materials like glass, carbon and Kevlar pulp. Brake pad formulations were made using CNSL (cashew net shell liquid) modified phenolic resin as a binder, graphite or cashew dust as a friction modifier and barium sulphate, talc and wollastonite as fillers. Influence of each component on the hardness value has been studied and a proper formulation has been arrived at to obtain hardness values around 35 on Scleroscopic scale. Friction and wear properties of the respective brake pad materials have been measured on a dynamometer and their performance was evaluated.

Asbestos is being replaced throughout the world among friction materials because of its carcinogenic nature. This has raised an important issue of heat dissipation in the non-asbestos brake pad materials being developed for automobiles etc. It has been found that two of the components i.e. carbon fibres as reinforcement and graphite powder as friction modifier, in the brake pad material, can playa vital role in this direction. The study reports the influence of these modifications on the thermal properties like coefficient of thermal expansion (CTE) and thermal conductivity along with the mechanical properties of nonasbestos brake pad composite samples developed in the laboratory.