For manufacturers and engineers focused on brake system reliability, the right additives make all the difference—and at Bull Chemicals, our copper powder is a game-changer for brake pad formulations. Let’s dive into the core performance improvements it delivers to brake pads.
Table of Contents
First: Enhances Thermal Conductivity to Prevent Overheating
Brake pads generate intense heat during braking—temperatures can reach 500°C to 800°C under heavy use. Copper powder, with a thermal conductivity of 401 W/(m·K) (far higher than most friction materials like resin or fiber), efficiently transfers this heat away from the friction surface. By adding 3% to 8% copper powder to brake pads mixture, we reduce heat buildup by up to 25%, preventing brake fade (a drop in friction force due to overheating) and extending the overall lifespan of brake pads by 15% to 20%.
Second: Stabilizes Friction Coefficient for Consistent Braking
A stable friction coefficient is vital for reliable braking—fluctuations can lead to unpredictable stopping distances. Copper powder acts as a “friction modifier” in brake pads friction materials: its soft metallic properties fill micro-gaps on the brake disc surface, ensuring uniform contact. Tests show that brake pads mixes containing copper powder maintain a friction coefficient of 0.35 to 0.45 (a standard range for safe braking) even across temperature changes from -30°C to 600°C, while mixes without copper powder see a 10% to 15% coefficient drop at extreme temperatures.
Third: Reduces Wear and Lowers Dust Generation
Wear resistance and low dust are key user demands. In our brake pads formula, copper powder forms a protective “transfer film” on the brake disc during use, reducing direct abrasion between the pad and disc. This cuts brake pad wear rate by 20% to 30% (compared to copper-free formulas) and lowers brake dust emission by around 18%. Additionally, copper’s ductility minimizes “noise-causing vibrations”—brake pads with copper powder produce 10dB to 15dB less noise during braking than copper-free alternatives.
Bull Chemicals’ copper powder is engineered to meet strict brake system standards, ensuring these performance benefits translate to safer, longer-lasting brake pads for both passenger cars and commercial vehicles.
