Brake Pad Noise Reduced by 60%

The Challenge

A major brake pad OEM supplier was experiencing noise, vibration, and harshness (NVH) complaints from vehicle manufacturers. Their semi-metallic friction material formulation showed inconsistent behavior under thermal cycling:

• Squeal and judder during high-temperature brake applications (300-500°C)
• Mu (friction coefficient) variation of ±0.15 across the operating temperature range
• Accelerated counterface wear on cast-iron rotors

The Solution

LSBT's metallurgical team reformulated the metallic component of the friction material:

• FeCu Pre-Alloy Powder — replaces mechanically mixed Fe + Cu, providing uniform Fe-Cu microstructure for consistent thermal conductivity and friction stability
• Sn-Cu Tin-Copper Alloy — acts as a low-melting bonding phase, improving wear resistance and reducing rotor scoring
• ZINC Powder — added as a friction modifier for high-temperature fade resistance

The Results

After reformulation with LSBT's pre-alloy powders, the brake pad achieved a stable friction coefficient (μ = 0.38-0.43) across 100-500°C. NVH complaints dropped by 60%, and the product was approved for three new vehicle platforms within six months.