Professional Documents
Culture Documents
Terrebonne, Canada
Changzhou, China
Fuji, Japan
Graphite and
Coke Powders
for Brake Linings
and Clutch
Facings
TIMREX®
Natural Flake Graphite TIMREX® Coke
TIMREX® Natural Flake Graphite is pro- TIMREX® Petroleum Coke is calcined at
duced in a wide range of products distin- appropriate temperature with low ash and
guished by particle size distribution, chem- sulfur content, well defined texture and con-
istry and carbon content. Timcal mines the sistent particle size distribution.
graphite from its own source in Lac-des-Îles,
Quebec, Canada. This unique “close-to-cus-
tomer” location guarantees very fast and
reliable deliveries.
All TIMREX® “Naturals” are thoroughly
controlled in our laboratories to ensure qual-
ity, consistency and above all, total customer
satisfaction.
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Typical values
TIMREX ®
Carbons for
Friction Materials
Ash Moisture Crystallite Tap DBP absorbtion
(%) (%) height density (Dibutylphthalate)
Lc (nm) (g/cm3) (g/100g)
T Graphite
T 75 0.07 0.1 > 100 0.21* 103
T 15-75 0.03 0.02 > 100 0.33* 70
T 150 0.09 0.05 > 100 0.51 59
T150-600 0.09 0.05 > 100 0.59 23
T 800 0.08 0.05 > 100 0.64 33
T 200-2000 0.08 0.03 > 100 0.73 21
0 500 1000 1500 2000
Particle size range d (µm) * Scott density
angular flakes, microporous Suitable especially for organic Good lubrication properties
bonded clutch facings (paper, fiber) Reduction of the friction level and smoothing
and organic brake linings of the friction coefficient
(semimetallic, non-metallic, Good thermal conductivity
low-metallic). Reduction of hot spots and difference thickness vibration
(DTV) by spring back and good thermal conductivity
High effectivness of wear-reduction at relatively low
graphite concentrations
Good damping behaviour due to internal lubricity
and micropores - noise reduction
Good wettability with organic binders and high adhesion
strength between binder and graphite particle
Carbons for
Friction Materials
Ash Moisture Crystallite Tap DBP absorbtion
(%) (%) height density (Dibutylphthalate)
Lc (nm) (g/cm3) (g/100g)
Coke
FC 250 0.07 0.02 ~2.5 0.91 6.0
FC 800 0.07 0.02 ~2.5 1.00 6.0
FC 250-1500 0.07 0.02 ~2.5 0.90 5.6
flakes Suitable for all organic bonded Good transfer film formation
friction materials, especially for Good thermal conductivity
linings in drum brakes as well as in Excellent lubricating properties
brake pads for trains.
irregular Suitable for all kind of Low wear of counterpart due to low ash content
sintered and organic bonded Stable friction coefficient, non-fading
friction materials. High thermal stability
Reduction of noise, especially medium and high
frequency sounds
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Powder
Properties
Technical Centre.
0.4
0.3
0.2
0.1
0
0 50 100 150 200
Crystallite size (nm) - (Inspired by S.A. Griffith and S. Marsch)
Graphite Graphite
Properties: Properties:
Density and internal Damping behaviour
porosity
Measuring method The following effects are thus available to TIMREX® Graphites as fillers demon-
the user: strate excellent vibration damping proper-
The density of carbon particles is usually ties. The loss factor is generally used to
measured pycnometrically by the xylene • rough particle surface - define the damping properties of a material
method. good anchoring in the binding matrix. or damping system. The loss factor is meas-
• the required volume concentrations ured on steel plated rods coated with
are achieved with lower mass graphite-resin mixtures (80 parts per hun-
concentrations. dred resin [phr]) using the Oberst bending
Conclusion • closed micro/meso porosity vibration test.
and surface porosity increase the
Graphite has a theoretical density of 2.26 dissipation of sound waves at interfaces - For TIMREX® Graphites, loss factors of
g/cm3, and calcined petroleum coke about improving damping behaviour. 0.07 to 0.08 were measured in the tests.
2.05 g/cm3 whereas tap densities are rela- These values are approximately 6 times
tively low therefore high volume concentra- greater than those for unfilled, coated steel
tions can be achieved using graphite and plate rods. The effect is caused by friction
coke even in relatively low quantities. between grains of graphite and resin within
the graphite crystallite, and grain-boundary
With TIMREX® Graphite powders, theo- diffusion (see also porosity).
retical density - excluding internal closed
pores - is achieved in the fine powders. TIMREX® Graphites contribute towards
As particle size increases, particle density vibration damping in brake linings, and
drops - an effect of internal closed porosity. thus help to reduce noise.
Micro- and mesopores in the range of
<100 nm are mainly involved.
2.300
2.200
2.150
2.100 KS
Density (g/cm3)
2.050
T
2.000
0 500 1000 1500 2000
Particle size d90 (µm)
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Graphite
Properties:
Oil absorption (DBP)
Measuring oil absorption to define the Conclusion The use of these graphite powders in lin-
characteristic features of carbon blacks is a ing compounds, gives the user greater free-
normal standard procedure. Use of this Absorption depends on particle size, bulk dom when formulating the mixture, and
method on other powders and fillers has density, specific surface area, crystallinity frequently permits an increase in the con-
shown that oil or dibutylphthalate (DBP) and the wettability of the surface. The pro- centration of fine-grained additives (e.g.
absorption values are helpful to determine portion of fines in the graphite powders has oxides, sulfides). Alternatively, the propor-
binder consumption in filled materials a particularly marked effect on absorption. tion of binding agent can be reduced which
(filled plastics, resin-bonded carbon brushes By reducing the amount of fines, DBP generally leads to a lower tendency towards
and organically-bonded friction modifiers). absorption, and hence binding agent con- fading.
sumption, drops substantially
(KS 5-75TT, KS 150-600SP, T 150-600
and 50x100 mesh FR).
Measuring method
Graphite DBP-Absorption
The oil absorption test is a special cen- (g/100g)
trifugation method showing high repro-
ducibility, developed by TIMCAL.
KS 5-75TT 45
A special centrifuge tube is filled with
0.5 g of TIMREX® graphite powder and KS 150-600SP 17
then covered with dibuthylphthalate
(DBP). After centrifuging for 90 minutes T 150-600 23
at a relative acceleration of 453 g, the tube
is weighed and the oil absorption of 100 g 50x100 mesh FR 11
of powder is calculated (based upon the
weight increase of the 0.5 g sample). FC 250-1500 6
Tube
Centrifugation
DBP
Sample
Filter
Sieve
Graphite
Properties:
Thermal conductivity
Graphite
Properties:
Spring back and
elasticity of single
particles
The force-displacement behaviour of sin- and elastic deformation properties. The high TIMREX® Cokes are characterized by a
gle carbon particles describes qualitatively plastic particle deformation causes smooth high level of grain stability. Their elasticity,
the mechanical properties of the particles as friction surfaces to form on the brake lining which is relatively high for cokes, reduces
particle strength, brittleness and elasticity and disc. At the same time the formation of a dust and hence wear and noise. By contrast,
and gives an idea about deformation mech- stable, dense and smooth transfer film is also gas and metallurgical coal cokes, which are
anism, wear and wear mechanism in the promoted. very brittle, tend to produce dust in the fric-
friction process. The relatively high elasticity reduces the risk tion process which leads to increased wear
of fatigue failure at the edges of the particles; and is linked to noise in the quiet zone.
it also reduces dust formation and wear in the
Load
lining.
Moreover, the elasticity of the graphite par-
ticles contributes towards the elasticity of the
entire lining. It helps to smooth out rough
spots on the surfaces, and increases the effec-
Displacement (% of particle height)
100
80 Natural
Wear caused by surface rough spots and noise
T
particle diameter caused by difference thickness vibration 60
Coke structure
The structure of coke is determined by oil
quality, the coking technology used and the
duration and temperature of the calcination
phase. TIMREX® Cokes have excellent tex-
tures with anisotropic flow and mosaic
structures to ensure a high level of grain sta-
bility and a relatively high elasticity.
Coke properties
TIMREX® Cokes are characterised by • TIMREX® Cokes are low in dust, owing
low and constant ash content (approx. to their grain fractions and the milling/
0,07%), low sulfur content (approx. 1%) screening processes used. They are therefore
and the absence of volatile substances. easy and clean to process.
• The low ash content accounts for the low • To guarantee good wetting properties and
rate of wear of brake linings with TIMREX® adhesion to the binding resin, no dust-
Cokes; no scoring can occur on the brake binding agents are used during production.
disc.
Application
properties of
model brake
linings
Graphite and coke
in sintermetallic
friction materials
Graphite
Graphite is the main additive in many Cu
friction materials - the proportions by vol-
ume used are frequently up to 30%. Other
additives are oxides such as Al2O3, SiO2,
carbides such as SiC or chromium carbides
and cokes. The friction behaviour of the
lining is essentially dependent upon the
type of graphite used, the grain size and the
concentration.
Application
properties of
model brake
linings
Graphite and coke
in sintermetallic
friction materials
0.3
0.2
0.1
0
T 44 T 75 T 800 T 150-600
Graphite type
0.2 0.2
Wear (mm)
0.1 0.1
0 0
T 150-600 KS 150-600SP
Graphite type
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Application
properties of
model brake
linings
Graphite and coke
in sintermetallic
friction materials
Graphite Method
Set the required friction coefficient Additive formul. 1 formul. 2 formul. 3 formul. 4
in a range from 0.38 to 0.45.
Level off the friction curve. Graphite 80 40 20 10
Reduce wear and tear on disc
and lining. Baryte 0 40 60 70
Alumina 16 16 16 16
The suitability of a raw material for a
specific brake lining can only be clearly Phenolic resin 4 4 4 4
established in a dynamometer test and by
vehicle road tests. However, tests using
diameter: 14.3 mm
model linings on friction testbeds can
height: 4 mm
frequently give an indication of the tri-
Investigated graphite
bological behaviour of graphites, and can Parameter Natural T 800 Natural T 200-2000 powders
be an aid to formulation. graphite 1 graphite 2
Test equipment:
Application
properties of
model brake
linings
Graphite and coke
in organic bonded
friction materials
period, and reaches the required friction function of graphite type and graphite
0 concentration after the period
level immediately with the least friction of bedding, friction load: 15 lbs
80 40 20 10 80 40 20 10 80 40 20 10 80 40 20 10
coefficient fluctuations.
Graphite type / graphite content (%) Courtesy: ITT Automotive
500 0.6
Temperature (°C); hydr. pressure (bar)
0.5
400
0.4
Method 300
0.3
Friction coefficient µ
200
Test samples 0.2 T-disc
Model brake pads 100 friction
0.1 coefficient
T-brake
Formulation 90% coke, 10% Phenolic resin hydr. pressure
0 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Thickness 12 mm Time / stops
Surface area 35 cm2 TIMREX® Cokes are characterised by a Fading behaviour of FC 250-1500 in
high friction coefficient and low wear - espe- model brake pads (90% coke, 10%
phenolic resin,
cially by contrast with other petroleum and compacting pressure: 200 bar
metallurgical coal cokes. The friction coeffi- curing temperature: 160 °C)
Test equipment:
cient of the brake lining can be influenced by
the grain size of the TIMREX® Coke. A con-
Dynamometer
stant friction coefficient throughout a wide
Special TIMCAL procedure
temperature range, and excellent fading
(modified VW-Audi test)
behaviour during successive stop brake appli-
cations is of importance to the user.
Leading the way.
Offered by your local Distributor/Agent: TIMCAL Japan K.K. TIMCAL Canada Inc.
Representative Office 990 rue Fernand-Poitras
7F Sagamiya Bldg. Terrebonne (Québec)
6 Ichibancho Chiyoda-ku Canada J6Y 1V1
Tokyo 102-0082 Japan Phone: +1 450 622 9191
Phone: +81 3 3511 2078 Fax: +1 450 622 8692
Fax: +81 3 3511 2077 info@ca.timcal.com
info@jp.timcal.com
TIMCAL Belgium SA
TIMCAL in France Av. Louise 534
Representative Office B-1050 Bruxelles, Belgium
FRICT. 09.2003