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Indian Institute of Technology (IIT) Roorkee 
Aluminium powder based stator brake pads/disc for light, medium and heavy duty automobiles and the materials thereof 
P.S.Mishra, Kamlesh Chandra and A. K. Chaturvedi 
Indian Institute of Technology (IIT) Roorkee 
Application type:
Applied - 2010-01-27 
Application Number:
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Indian Institute of Technology (IIT) Roorkee 
In accordance with this invention, aluminum brake-pads and discs consist of two major parts namely friction layer and back plate, which are required to be joined effectively such that these two layers do not separate out during brake application. Joining of such large area with aluminum is considered impossible if the back plate chemistry is not aluminum based. Therefore, aluminum powder based back plates and friction materials are provided, having the compositions as herein described. The composition for manufacturing the back plates comprises atomized aluminum powder in 60 to 85 wt% mixed with silicon carbide powder in 15 to 40 wt%. The aluminum powder has a particle size in the range of ≤120 µm and the silicon carbide has a particle size of ≥50 µm to 75 µm. The composition for the construction of the friction layer comprises aluminum powder in 70 to 90 wt%, silicon carbide (coarse) in 6 to 25 wt %, antimony sulphide (Sb2S3) in 1 to 2 wt %, Barium sulphate (BaSO4) in 1 to 4 wt% and coarse graphite flakes in 2 to 8 wt%, graphite (fines) in 2 to 6wt% and zinc optionally in ≤ 4 wt%. The constituents are selected to have particular size of the particles. The particles size of aluminum powder is ≤ 120 µm, silicon carbide from 200 to 250 µm, coarse graphite flakes from 200 µm to 350 µm, fine graphite powder ≤ 120 µm, Sb2S3 from ≤ 40 µm, BaSO4 ≤ 40 µm, and zinc ≤ 75 µm. These powder compositions cover the entire range of materials required for light to heavy duty brake applications.  

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