The present invention provides a sintered metal friction material that has excellent wear resistance, heat resistance even at high load and has a higher friction coefficient while maintaining a friction coefficient and wear resistance that are hard to decrease, and has a reduced content of copper of less than 5 mass %. There is provided a sintered metal friction material characterized in that the sintered metal friction material comprises a sintered material of a friction material composition, the friction material composition comprises matrix metals and a friction modifier, the matrix metals comprise following 20 to 40 mass % of iron powder, 20 to 40 mass % of nickel powder, 0.5 to 10 mass % of zinc powder, 0.5 to 5 mass, of tin powder, 0.5 to 4 mass % of copper powder and 0.5 to 5 mass % of sintering assist powder.

An electromechanical brake actuator (2) includes a housing (1), a first housing part (3) configured as a housing flange for attaching the electromechanical brake actuator (2) to a disc brake (38), a second housing part (4) for receiving a drive (6), a third housing part (5) arranged between the first housing part (3) and the second housing part (4) and connected to the first housing part (3) and the second housing part (4), a motor (37), a gearbox (7), and a tappet (9) or a spindle for actuating a disc brake (38). The housing (1) is an aluminum die-cast formed part. The first housing part (3) and the second housing part (4) have planar contact surfaces (34, 34a) configured to receive plates of a two-plate die-casting machine during the forming process of the housing (1).

It has been found that metal parts having rough surfaces can be manufactured by (1) compacting a metal powder under high pressure in a mold to make a green part, wherein at least one face of the mold is roughened by electrical discharge machining to have an R.sub.a of 10 to 200 micro-inches, as measured with a profilometer having a stylus tip, (2) heating the green metal part to a temperature of at least 1500 F. to sinter the green metal part to produce the metal part having at least one rough surface, wherein the rough surface has an R.sub.a which is within the range of 10 to 200 micro-inches, as measured with a profilometer having a chisel tip, and (3) optionally, buffing, classifying, deburring and/or washing the metal part. This method can be beneficially used in manufacturing clutch plates, pressure plates, and cam shaft sprockets.

The present invention is concerned with a frictional material composition not containing copper as an element or having the content of copper of 0.5 mass % or less, the composition containing a cashew dust; (A) potassium titanate; (B) one or more selected from the group consisting of lithium potassium titanate and magnesium potassium titanate; and (C) one or more selected from the group consisting of zirconium silicate, zirconium oxide, and magnesium oxide, wherein the content of the cashew dust is 1 to 10 mass %, and the content of the component (C) is 11 to 30 mass %.

An improved friction material is described, comprising a binding composition based on a hydraulic binder, and its use in brake pads and industrial applications.

Brake calipers, molds and method of producing brake calipers are disclosed including a brake caliper mold for molding a brake caliper, the brake caliper mold comprising: a first mold section; a second section half; a core member configured to form a piston bore, the core member comprising: a tower configured to form a tower window in a bridge of the brake caliper and a piston bore extension to form a piston bore of the brake caliper; and four locator forming surfaces located on the tower, each of the four locator forming surfaces configured to form a separate lateral data reference surface on the brake caliper, the lateral data reference surfaces capable of being used for subsequent machining of the brake caliper to predetermined tolerances.

To provide the manufacturing method for a copper and elemental copper free NAO friction material providing an excellent fade resistance and high mechanical strength. [Means to Resolve] This manufacturing method includes the mixing step of mixing the raw friction material compounds to obtain the raw friction material mixture, the kneading step to apply the raw friction material mixture in the sealed type kneader to knead while maintaining the melting temperature of the thermosetting resin in the kneader or higher but lower than the curing temperature (temperature to start curing) under the predetermined pressure to obtain the kneaded raw friction material, the sizing step of sizing the kneaded raw friction material to obtain the raw friction material granulation article, and the hot press molding step of filling the raw friction material sized particles in the molding die to hot press molded by the press machine.

Aluminum alloys, in particular Al magnesium or Al titanium alloys, are suitable as corrosion protection media in friction linings for automotive brakes and couplings, and serve as a replacement for zinc metal or zinc compounds in such linings.

A method of making a ceramic matrix composite (CMC) brake component may include the steps of applying a pressure to a mixture comprising ceramic powder and chopped fibers, pulsing an electrical discharge across the mixture to generate a pulsed plasma between particles of the ceramic powder, increasing a temperature applied to the mixture using direct heating to generate the CMC brake component, and reducing the temperature and the pressure applied to the CMC brake component. The ceramic powder may have a micrometer powder size or a nanometer powder size, and the chopped fibers may have an interphase coating.

Provided is an alkali metal titanate which, when used as a constituent material of a friction material, is excellent in heat resistance and friction force and capable of effectively suppressing wear of a mating material disposed to face the friction material. The alkali metal titanate includes a sodium atom and a silicon atom. The content of the sodium atom is 2.0 to 8.5 mass %. The content of the silicon atom is 0.2 to 2.5 mass %. The ratio of the content of an alkali metal atom other than the sodium atom to the content of the sodium atom is 0 to 6.