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Case studies / Friction
Where are we coming from? From Asbestos-based to NAO Copper-free
A joined effort among manufacturers, regulatory organizations and the automotive industry has brought a noticeable evolution on the composition of the friction materials

All machine in movement needs to be stopped at some moment. The brake is responsible to turn this kinetic energy into heat and release it through the interface.

This is the everlasting basis of the friction industry. Actually, during a normal braking, the disc is responsible to dissipate around 80 % of the heat generated by friction. The temperature can raise up to 600-700 ºC in rough conditions. As a result of the energy involved in this process, tribo-chemical reactions and erosion always take place.

The chemical composition of the brake PAD then, is directly related with the performance of the whole brake system.

Every time you stop your vehicle, a small amount of material is released in form of PM10 and PM2,5, small enough to be caught in air turbulence and easily enter human airways.

Depending on their composition, can be quite harmful to wildlife as they might contain metals such as copper, chromium, lead, antimony and metal oxides.

Considering that around 21% traffic-related PM10 emissions come from brake wear, automotive industry, raw material manufacturers and regulatory organizations have a shared responsibility to follow up dust emissions released during braking, and come up with innovative solutions to overcome this environmental threat.

Up to the 1980's
Asbestos
Asbestos linings were used on virtually all vehicles. Asbestos was and still is an excellent fibre for brake linings. It offers good strength, temperature and chemical resistance, and is cheap compared to other materials that are used for the same purpose. But the physical properties that make asbestos such a good fibre also make it a hazardous substance, as it can produce asbestosis.
The arrival of front-wheel drive
Metal-based materials
The arrival of front-wheel drive required semi-metallic front disc brake pads that could withstand higher operating temperatures. But they had their own troubles, such as the increase of noise and vibrations, and also the amount of grey/black dust produced. The industry evolved to offer a wide range of additives to equilibrate the formulas depending on the application and reduce these drawbacks.
New challenges arrived
NAO and Low-met
Manufacturers started also to develop formulas with lower and even none content of steel (NAO) using alternative reinforcement materials such as rock wool, polymeric fibres and non-ferrous metals.

Copper, brass and bronze became materials of general use because of their contribution to the performance and wear at high temperature and also because of their good NVH properties, and where in the origin of RIMSA as supplier for the friction industry, providing high quality recycled chips of brass and bronze.

At rimsa we were pioneers on manufacturing lead-free brass and bronze chips 20 years ago

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.

These are the products used in this case, go take a look at its specs
Friction
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      Case studies / Friction
      REACH changes its normativity on the labeling and SDS of brass containing Pb
      As of January 5, 2021, manufacturers/distributors on the EU market of brake pads will not only to notify downstream customers of the presence of SVHCs but ECHA itself as well if it contains a whole contain > = 0.1 % Pb (SVHC)

      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) :

       · Repr. 1A, H360FD: May damage fertility. May damage the unborn child

       · Lact. H362: May cause harm to breast-fed children

       · STOT RE 2, H373: May cause damage to central  nervous system, blood and kidneys through prolonged or repeated exposure by inhalation and ingestion

      At rimsa, we manufacture our own alloy on a unique completely dry process without including lead on the mixture

      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:

      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

      A large number of OE and Aftermarket manufacturers, including the big groups on friction industry, have already chosen our well-known ecoChip as their seamless ally to remove lead of their formulations and we want to share our expertise with those companies who want to go one step further on their ecological commitment

      On the other hand, many other companies might consider to replace brass for a different material, and we want to be on their side too

      The latest results from our trustworthy partners reveals that our ecoCast ,certified EN GJL 250 cast iron chips , can replace brass chips and maintain the same performance on existing formulations

       

      These chips are able to provide heat conductivity and damping properties thanks to the graphite flakes segregated from the matrix, which turns this material into a self-lubricated chip that can provide a wear reduction and in the overall, become an alternative material to brass for those partners willing to remove any copper-containing product from their formulation

      Friction
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        Sant Feliu de Llobregat Barcelona, Spain

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        +34 93 666 46 11 / +34 635 519 002

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          Case studies / Friction
          Different strategies to remove copper from existing formulations
          What started many years ago in the political corridors in the US, has risen as a priority project for almost all material development laboratories across the globe

          Being automotive such a globalized industry, a concern that has sprung up on a specific market, can quickly become into a worldwide trend if it is properly justified by a greater good.

          A clear example of it can be seen on the friction industry. What started many years ago in Washington and California, when copper considered as main cause for the extinction of salmon and rainbow trout, due to its neurotoxic behaviour in fish , has become into a priority project for almost all material development laboratories across the globe. Nevertheless, even there are still some grey areas to clarify, it is clear that the main brake system & vehicle manufacturers are already requiring copper-free formulations

          Friction industry is going on this lead but that’s not an easy job, as not a single solution has emerged as direct replacement for this material with unique properties. Engineers and friction material formulators must come up with new strategies to replace this non-ferrous metal if they want to stay on the run.

          In our experience, there are different strategies to address this challenge, involving different materials depending on the scenario

          To begin with, for those companies using this metal on its pure form, they can start by reducing the %Cu of it, as 5% Cu will be allowed until 2025. We will address this case more deeply on an incoming case study. 

          Other companies, however, are using already a very small amount of copper on the overall of their formulations. Either because they are using a brass instead of copper or because the %Cu by itself is very low.

          In this case, our certified EN GJL 250 cast iron chips, better known as ecoCast, can become an alternative material to brass for those partners willing to remove any copper-containing product from their formulation, thanks to their overall properties.

          These chips are able to provide heat conductivity and damping properties thanks to the graphite flakes segregated from the matrix, which turns this material into a self-lubricated chip that can provide a wear reduction

          We are glad that so many companies have been able to develop their own Copper-free materials by using rimsa’s enviroLube as their key additive. Why so?

          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?

          EnviroLube differential chemical behaviour has been proved effective to provide optimal performance, even replacing copper in existing formulations. Now is being used in Cu-free OE, OES and AM applications all around the globe. Depending on the grade, our customers will find the right choice for their application

          It is a family of high-performance additives that contain low melting point phases, which undergo an endothermic reaction. It provides cooling capacity, helping not only to increase heat removal capacity, but also to reduce the working temperature, considered a key parameter to be aware of either on NAO as well as aluminium-based formulations

          Moreover, due to its particular composition, it releases in a controlled manner tin sulfide in the working surface, which is generated in-situ on the working surface of the friction material, helping on the high temperature sections to maintain good performance

          Friction
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            Contact us
            We would love to talk about your next project

            Do not hesitate to contact us for any question or requirement you may have. We will be happy to collaborate with you

            Visit us

            Armenteres s / n – Pol.Ind. MATACÀS- Nave 21 08980

            Sant Feliu de Llobregat Barcelona, Spain

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            +34 93 666 46 11 / +34 635 519 002

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            friction@rimsa.com

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              Case study / Fricción
              Our quality department

               

               

              At rimsa we dedicate all our efforts to ensure excellent quality in each of our products and services, guaranteeing the satisfaction of all customers.

              Our quality department, made up of highly qualified people with vast experience, guarantee the management of all processes according to the ISO9001: 2015 standard.

               

              We are committed to continuous improvement in order to optimize our productivity and quality, which begins with the selection of suppliers and strict quality control of all raw materials. From here we adhere to strict control plans that we apply in all operating processes, until the product is received by the customer.

              We are proud that this effort is recognized by customers, who in the 2019 satisfaction survey rated us with the highest marks in terms of product quality, confidence in rimsa and responsiveness, having stated 52% of the same an increase in the quality perceived in the last 5 years.

               

              Thus, we aspire this 2020 to meet for the sixth consecutive year our goal of 0% customer rejection of manufactured product (0 defects), and for the fourth consecutive year of our commercialized products.

              We guarantee the highest quality standards

              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.

              Characterized by an excellent Quality Management System

              Rimsa has been certified by ISO9001 since 2001. As a company that assumes the principles and requirements established by ISO 9001, we adhere to our commitment to quality and recognize that customer satisfaction and continuous improvement are two essential elements. for our organization.

              This year 2020 we will also certify our commitment to continuous improvement in environmental management, as we will complete the integration process of ISO14001. We believe that this is a universal tool that allows evaluating an organization’s efforts to achieve adequate and reliable environmental protection.

              Friction
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                Contact us
                We would love to talk about your next project

                Do not hesitate to contact us for any question or requirement you may have. We will be happy to collaborate with you

                Visit us

                Armenteres s / n – Pol.Ind. MATACÀS- Nave 21 08980

                Sant Feliu de Llobregat Barcelona, Spain

                Call us

                +34 93 666 46 11 / +34 635 519 002

                Write to us

                friction@rimsa.com

                Or leave us a message and one of our agents will contact you