The invention provides a coating film having excellent adhesion, even without a chemical conversion film treatment being carried out as an undercoat treatment, and a metal automotive part having the coating film. A powder is deposited by powder-coating onto the surface of a metal automotive part that has been quenched after forging, and tempering of the metal automotive part and bake-hardening of the deposited powder are carried out simultaneously, thereby forming a skin film on the surface of the metal automotive part. The surface of the metal automotive part before the powder is powder-coated thereon is a work-hardened basis material surface that has been not subjected to a chemical conversion filming treatment.

Systems, devices, and methods are provided for manufacturing a carbon ceramic brake disc. Generally, a plurality of uncured or partially-cured bulk molding compound preforms or molding compound layers and ventilation cores are placed in a mold cavity and warm-pressed at a first temperature. The ventilation cores are removed from the resulting cured green body. The cured green body is then removed from the mold, and treated through a polymer infiltration and pyrolysis or reactive melt infiltration process. Certain steps can be repeated until a desired target density or weight is attained.

A friction assembly has a support plate, at least one brake pad and at least one reinforcing foil of the plate. The brake pad and the support plate are co-moulded from at least one heat-resistant resin. The reinforcing foil is fixed to the support plate via anchoring projections, joined to and which extend away from the foil, embedded in the resin to prevent or limit deformations of the support plate in the use of the assembly.

A friction material composition containing an alkali metal salt as a friction adjusting material. The alkali metal salt is spherical and porous. The alkali metal salt has an average particle diameter of 20 m to 240 m. A friction material is produced by using the friction material composition.

Provided by the present invention are: a non-asbestos frictional material composition containing a binder, an organic filler, an inorganic filler, and a fiber substrate, wherein, in the non-asbestos frictional material composition, content of a copper is 5% or less by mass as a copper element, content of a metal fiber other than a copper fiber and a copper alloy fiber is 0.5% or less by mass, and a titanate salt is contained therein with antimony trisulfide or zinc powders, with content of the titanate salt being in the range of 10 to 35% by mass; and a frictional material and a friction member that use the said non-asbestos frictional material composition.

The invention provides a friction material and a method of making the friction material. The friction material comprises man-made vitreous fibres whose chemical composition comprises: less than 2 wt % Fe.sub.2O.sub.3; 30-40 wt % MgO+CaO; 35-45 wt % SiO.sub.2; 17-24 wt % Al.sub.2O.sub.3; and 1-5 wt % K.sub.2O+Na.sub.2O.

A friction material composition including a fiber substrate, a binder, an organic filler and an inorganic filler, wherein the content of copper in the friction material composition is 5% by mass or less in terms of elemental copper, and the friction material composition includes magnesite as the inorganic filler.

A non-asbestos frictional material composition is provided, which is capable of provide a frictional material with low environmental load and with excellent friction coefficient, anti-crack properties, and abrasion resistance compared with conventional ones. Furthermore, a frictional material and a friction member formed by using this non-asbestos frictional material composition are provided. The non-asbestos frictional material composition containing a binder, an organic filler, an inorganic filler, and a fiber base material includes: copper in a content of 5 mass % or less as a copper element; a metal fiber other than a copper fiber and a copper alloy fiber in a content of 0.5 mass % or less; and mica and graphite with a particle size of 90 m or less but not containing graphite with a particle size of more than 90 m.

A clutch friction material includes a base material containing a rubber material and a thermosetting resin. The clutch friction material also includes an intermediate layer disposed on the base material. The intermediate layer includes either a glassy carbon structure or a graphite structure formed as a result of thermal curing of the thermosetting resin contained in the base material. In addition, the clutch friction material includes an outermost surface layer disposed on the intermediate layer. The outermost surface layer contains a pyrolysate produced as a result of pyrolysis of rubber and resin components contained in the base material.

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.