Полуметаллический состав для влажного климата: Бразилия
Клиент
An aftermarket brake brand in São Paulo, Brazil
Отрасль
Aftermarket Brake Brand
Ключевые показатели
Задача
The brand's existing pad was an organic compound that worked well in the dry and poorly in the wet. On the steep descents around São Paulo state, riders reported fade after repeated braking and a squeal that appeared only in rain.
Uneven wear was the second complaint. Pads were wearing taper — thin at the leading edge, thick at the trailing — which pointed at pad mobility in the caliper rather than at the friction material alone.
The brand also needed documentation it could hand to distributors: friction, shear and wear test reports per batch.
Наше решение
We reformulated and then fixed the hardware around the new compound.
- Compound: semi-metallic with a friction coefficient of 0.42 ± 0.03, stable from ambient up to the fade threshold, which is where the organic pad had been falling away.
- Surface: scorched to remove residual binder, so the bedding-in period drops and the first wet stops behave predictably.
- Noise: slot and chamfer on the friction face, plus a rubberised shim on the backing plate — the shim did more for the squeal than the compound change.
- Fit: pad ears sized to the caliper bracket with a small clearance, which removed the taper wear.
- Traceability: batch number on the backing plate, linked to a retained test report.
Результат
Noise complaints dropped 61% over the first six months, and the taper wear reports stopped. Fade complaints on the steep descents were replaced by feedback that the lever felt consistent through a long descent.
The brand moved its whole pad range onto the new compound family over three orders, and now ships the per-batch test report with each carton as a distributor-facing selling point.
What fade actually is
Friction material works by converting kinetic energy into heat. When the pad cannot shed that heat fast enough, the binder at the surface starts to decompose and a gas layer forms between pad and disc. That layer is what the rider feels as a lever that goes long and a bike that will not stop.
Organic compounds fade earlier because their binder content is higher. Semi-metallic compounds trade a little cold bite and disc wear for a much higher and flatter temperature ceiling — which is the right trade on a descent, and the wrong trade for a bike that only ever runs city errands.
Why the shim solved the squeal
Squeal is vibration, not friction. The pad, caliper piston and bracket form a system with a resonant frequency, and if the friction excitation lands on it the whole assembly rings. Changing the compound shifts the excitation. Adding a rubberised shim adds damping at the interface, which suppresses the resonance regardless of where the excitation sits.
That is why a noise complaint is often cheaper to solve with a shim than with a reformulation — and why we check the hardware before touching the recipe.
What to ask a supplier for
Ask for the friction coefficient at temperature, not just at ambient. Ask for the shear strength of the bond between friction material and backing plate — that is the failure that actually endangers a rider. And ask for batch traceability, because a compound that tests well once proves very little about the carton in the warehouse.
Ключевые моменты проекта
- Гибкая методология разработки
- Выделенный менеджер проекта
- Поддержка и обслуживание 24/7
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