On the other side, recyclability regulations in the latest 1990´s for vehicles in Europe (End-of-life directive 2000/53/EC) states a maximum content of metals such as Pb, Hg and Cr(VI) <0,1 %. and Cd <0.01 %. Friction materials were a source of Lead. It was common to use lead sulphide as lubricant and lead derivatives were regular contaminants in natural products such as pyrite (natural FeS2), sometimes up to 10%.

Since more than 20 years ago, our unique manufacturing process enables us to offer the OE’s choice of lead-free CHIPS with the best value-for-money.

Recycled brass chips & swarfs are produced during the mechanization of big brass pieces to obtain products such as decorative pieces, taps, balustrades, profiles etc.

These pieces must be machinable, otherwise it would be impossible to obtain the necessary shapes required on these fields. To do so, the standard alloy available in the industry contains 1 -3 % of Pb, as this metal improves its manufacturability. 

So far, CLP considered that an alloy is considered a mixture, that, if it do not present any hazard to human health by inhalation, ingestion or contact with skin or the aquatic environmental in the form they are placed on the market, do not need CLP label. 

What has changed is that lead, even in its massive form, as agreed in ATP09 at REACH Registration, if it is in a concentration 1-3 % it will contribute to the classification of the mixture with the following indications (which must be indicated on the label) :

According to Law 8/2010, not labeling a product according to CLP (being aware of its dangers) is considered a serious offense, penalized with fines from 6.001 € to 85.000 € 

Therefore, the alloy must be labeled with lead hazards and the SDS must be updated from June 2020, following the indications below:

• Our Brass chips are considered a MIXTURE, that contains lead, considered SVHC (Substances of Very High Concern). 
• Brake PADS/Blocks/Linings are considered ARTICLES (products where shape, surface or design determines its function to a greater degree than does its chemical composition).
• As of January 5, 2021, manufacturers/distributors on the EU market of brake pads (articles) will not only have to notify downstream customers of the presence of SVHCs but ECHA itself if it contains a whole contain > = 0.1 % Pb (SVHC).

So, for those companies using the standard lead-containing brass in the industry, to avoid this new regulation, must remove this material from their formulations?

Obviously not, taking the lead from the mixture, all these companies will be able to continue using this fundamental product on so many formulations. But lead-free brass is not a standard on the industry and the well-known chopped lead-free brass wools become excessively expensive due to its manufacturing process

To obtain a top-notch friction material, it is not enough to protect the phenolic resin. Indeed, it is a key parameter the control the performance and wear of the finished product. However, HOW this organic binder decompose is a crucial factor that will determine the comfort and the NVH properties of the pad.  Can we control this? Let’s go deep on that.

We start from the fact that the mentioned phenolic resin transforms into a sticky substrate on the friction surface when it degradates. And, as if it was like a smoker/non-smoker lung, a cleaner surface will help us to avoid groan, noise and vibrations, while obtaining a smooth and stable braking. And how can we do so? The answer is on titanates.

This way, we obtain a cleaner surface and so, when the counterpart contacts the friction material, we do not have that viscous residue between them which, as you might have guessed, will help us to reduce the CoF (μ) amplitude and improve μ stability, which are straightly related with the NVH and groan properties of a friction material.

Nowadays, there are a wide range of titanates with different morphologies and chemical compositions in the market. However, titanates commonly available in friction industry are a fibrous product with health issues. To make them fibre-free either the production costs are increased or they contain other metals on their composition.

On that lead, since 2019 rimsa has join forces with TAM Ceramics to tackle the challenges concerning this particular aspect of a friction material performance with innovative products specially developed for friction industry.

Finally, other companies have opted to create new copper-free formulations either by reformulating an existing copper-containing mix or creating a new one.

The key point to achieve a balanced formulation goes through being able to create a stable transfer layer while protecting phenolic resin from degradation in order to protect the integrity of the whole friction material.

The high heat dissipation capacity of copper combined with its ability to create primary plateaus makes impossible to find a direct replacement. So, if there is not a harmonized solution, there’s at least a successful strategy to address this challenge?

Polyacrylonitrile (PAN) is a synthetic resin prepared by polymerization of acrylonitrile.

It belongs to the important family of acrylic resins and is a tough and rigid thermoplastic material that, resistant to most solvents and chemicals, burns slowly and has a low permeability to gases.

Fibers obtained by precision cutting in a wide range of cutting diameters and lengths are used for REINFORCEMENT in a wide variety of industrial applications. These include the manufacture of adhesives, castings, composite materials (“composites”), filters, acid battery plates, paints, paper, sealants and refractory materials.

It is considered an added-value polymer as, besides of reinforing the application where it is included, this material has intumescent behaviour (fire protective) and several studies reveal an increase of the matrix-fibre union strength compared to other traditional fibres on mortars and pavements.

Having made the recycled product the base of our initial growth, our objective is to ensure that the raw material received and the intermediate product are properly analyzed and obey the specified parameters in order to guarantee a homogeneous final product, which complies not only with the specification, but ensure stable performance.

Regarding the products that we commercialize, the selection of suppliers is essential. From rimsa we guarantee compliance with the specifications before each shipment, with a specific control plan.

Engineers and designers must come up with formulations balanced in several characteristics:

– LOW  SQUEAL: Due to the high impact involved in railway applications

– HIGH HEAT DISSIPATION CAPACITY: Due to the high energy involved in railway applications

– WEAR AND CORROSION RESISTANCE: To reduce wear rate and increase the service life of the blocks

– LIGHT WEIGHT: And stable friction coefficient

– ACCEPTABLE COST: Versus performance

Our unique dry manufacturing process enables us to offer an OE quality product with the best value-for-money.

– Several grades with different particle sizes and chemical composition, to meet customer requirements

– Bronze contains Tin inclusions distributed that provide lubricity and cooling, reducing wear and improving the NVH characteristics

– Saves up to 20% compared with traditional bronze chopped wools

–The high thermal conductivity provides heat dissipation capacity, contributing to the stabilization of μ and reducing wear