In the production of clutch facings friction materials, Copper Powder has emerged as a significant additive in clutch facings mixtures and mixes. Its unique physical and chemical properties endow clutch facings with distinct characteristics, which are crucial for clutch performance.

Copper powder has an extremely high thermal conductivity, around 386 W/(m·K). When added to the clutch facings mixture, it can effectively enhance heat dissipation. In a test where clutch facings with 20% copper powder by volume were continuously operated under high – friction conditions for 60 minutes, the maximum temperature on the surface of the clutch facings was 30 – 40°C lower than that of clutch facings without copper powder. This remarkable heat – dissipation ability is vital for preventing the clutch facings from overheating and maintaining their performance during intense use.

With an electrical conductivity of about 5.96×10⁷ S/m, copper powder can also bring certain electrical – conductive properties to the clutch facings. Although this is not a primary property for clutch facings, in some special applications where electrostatic discharge or electromagnetic compatibility is required, the electrical conductivity of copper powder can play a role. For example, in hybrid – electric vehicle clutches, the presence of copper powder can help dissipate static electricity generated during operation.

The particle size of copper powder used in clutch facings typically ranges from 10 – 100 μm. Smaller particles (10 – 30 μm) can provide better dispersion in the clutch facings mixture, resulting in a more homogeneous structure. Larger particles (50 – 100 μm), on the other hand, can contribute to the mechanical interlocking within the mixture, enhancing the overall strength of the clutch facings. In a well – formulated mix, a proper combination of different – sized copper powder particles can optimize the performance of the clutch facings.

As mentioned above, the high thermal conductivity of copper powder enables efficient heat dissipation. In high – performance sports cars, where the clutch experiences frequent and intense engagement and disengagement, clutch facings with copper powder can withstand more high – speed operation cycles without thermal failure. A test on a sports car’s clutch showed that the clutch facings with 25% copper powder could endure 50% more high – speed engagement cycles than the standard clutch facings before reaching the critical temperature limit.

Copper powder can enhance the wear resistance of clutch facings. In a wear – test carried out for 150,000 clutch engagement cycles, the wear rate of clutch facings with 15% copper powder was reduced by 35 – 40% compared to those without it. The presence of copper powder helps to form a more wear – resistant surface layer on the clutch facings, extending their service life.

Copper powder has good compatibility with most of the common matrix materials used in clutch facings, such as various resins and rubbers. In a compatibility test, the adhesion strength between copper powder and a typical resin – based matrix was 30 – 40% higher than that of some other additives. This high compatibility ensures that the copper powder can be well – integrated into the clutch facings mixture, maintaining the integrity and performance of the clutch facings.

Copper is a relatively expensive metal, which makes the use of copper powder in clutch facings production increase the material cost significantly. Compared to some low – cost friction materials, using copper powder can raise the material cost of clutch facings by 40 – 60%. This cost factor may limit its widespread application in some price – sensitive markets.

Copper powder is prone to corrosion in the presence of moisture and certain chemicals. In a humid environment with a relative humidity of over 80% and in contact with acidic substances, the copper powder in the clutch facings can corrode. In a 3 – month exposure test in such an environment, the corrosion rate of copper powder in the clutch facings was about 5 – 8% by mass, which can lead to a decrease in the mechanical and electrical properties of the clutch facings.

The density of copper powder is relatively high, about 8.96 g/cm³. When added to the clutch facings mixture, it can increase the overall weight of the clutch facings. In a clutch facings mix with 20% copper powder by volume, the weight of the clutch facings increased by 15 – 20% compared to the base mixture without copper powder. This increase in weight may have a negative impact on the fuel efficiency and acceleration performance of the vehicle, especially in applications where weight reduction is crucial.

In conclusion, Copper Powder offers remarkable advantages in clutch facings production, including excellent heat dissipation, improved wear resistance, and good compatibility. However, its high cost, corrosion susceptibility, and density – related issues need to be carefully considered. Manufacturers need to balance these factors according to the specific requirements of different applications to fully utilize the potential of copper powder in the production of high – quality clutch facings friction materials.