The Application of Corundum in Brake Pads Production
In the intricate world of brake pads production, materials selection is crucial for ensuring safety and optimal performance. Among the various materials, corundum, especially in the form of corundum sand, has carved out a significant niche.
1. Corundum Sand in Brake Pads
Corundum sand is a granular form of corundum, which is highly valued in brake pads production. It has a high Mohs hardness of approximately 9, making it one of the hardest naturally – occurring minerals. This hardness endows brake pads with enhanced durability. For instance, in high – performance brake systems, corundum sand can endure the intense pressure and heat generated during braking, maintaining its structural integrity.
2. Incorporation into brake pads mixture
When formulating brake pads, corundum sand is combined with other elements to create the brake pads mixture. This mixture typically consists of binders, such as phenolic resins, which hold the components together; fillers like kaolin clay to adjust the density and cost; and other friction – modifying materials. In a standard brake pads mix, corundum sand usually accounts for 15 – 25% by weight. This proportion is carefully determined to balance the friction and wear characteristics of the final product. For example, a higher percentage of corundum sand can increase the friction coefficient but may also accelerate the wear of the brake pads and the associated rotors.
3. Role in brake pads friction materials
As an integral part of brake pads friction materials, corundum sand plays a pivotal role in regulating the friction coefficient. A well – designed brake pads friction material with the appropriate amount of corundum sand can maintain a stable friction coefficient in the range of 0.35 – 0.55 under normal braking conditions. This stability is essential for providing consistent braking force. Whether it’s a gentle stop at a traffic light in urban driving or a high – speed emergency stop on the highway, the stable friction coefficient ensures that the braking performance remains reliable.
Advantages of Using Corundum in Brake Pads
- Exceptional High – Temperature Resistance: Corundum can withstand temperatures reaching up to 1800°C. During aggressive braking, brake pads can experience a rapid increase in temperature. Corundum’s high – temperature resistance prevents the degradation of the brake pads friction materials. In fact, tests have shown that brake pads with corundum can maintain their friction performance even when the temperature exceeds 1000°C, ensuring reliable braking in extreme situations.
- Outstanding Wear Resistance: Thanks to its high hardness, brake pads containing corundum sand have a significantly longer service life. Research indicates that these brake pads can reduce wear rates by up to 40% compared to traditional brake pads without corundum. This not only extends the lifespan of the brake pads but also reduces the frequency of replacements, resulting in cost savings for vehicle owners in the long run.
- Superior Friction Stability: The presence of corundum sand contributes to a stable friction coefficient. This stability minimizes the risk of sudden changes in braking force, which could lead to skidding or loss of control. In high – speed driving scenarios, the consistent friction provided by corundum – based brake pads is crucial for safe and effective braking.
Disadvantages of Using Corundum in Brake Pads
- High Production Cost: The extraction and processing of corundum sand are relatively expensive. The complex mining and refining processes, along with the limited availability in some regions, drive up the cost. This increased cost can make brake pads with corundum less competitive in price – sensitive markets, where cost – effective alternatives are preferred.
- Rotor Abrasion: While corundum’s hardness is beneficial for the wear resistance of brake pads, it can be abrasive to brake rotors. Over time, the use of corundum – based brake pads can lead to increased wear of the rotors. In some cases, the wear rate of rotors can be up to 25% higher compared to using other non – abrasive friction materials. This means that vehicle owners may need to replace their rotors more frequently, adding to the overall maintenance cost.
- Processing Challenges: Corundum sand’s abrasive nature makes it difficult to mix evenly in the brake pads mixture. Achieving a homogeneous distribution of corundum sand in the mixture requires specialized equipment and precise processing techniques. If not properly mixed, the quality of the final brake pads can be inconsistent, leading to uneven braking performance and potential safety issues.