Porous copper powder modified friction material

In a brake system including an aluminum-metal matrix composite rotor, an actuation member, and friction pads wherein the actuation member in response to an operational input moves the friction pads into engagement with the aluminum-metal matrix composite rotor to effect a brake application, the improvement in the formulation of said friction pads to prevent degradation of the aluminum-metal matrix composite rotor while providing an average coefficient of friction of from 0.38-0.42 when an operational temperature of -40.degree. to 450.degree. C. is generated during a brake application, said composition comprising:

• 8-15 percent by weight of phenolic resin for said friction pads;
• 5-12 percent by weight of an organic friction modifier selected from a group consisting of rubber scrap, cellulose, latex, cork, and cashew particles to provide friction stability in the friction pads through the development of a glaze on the surface of the aluminum-metal matrix composite rotor during a brake application;
• 1-5 percent by weight of aramid fiber to aid in the initial processing the composition and to provide resistance to wear for the friction pads;
• 4-14 percent by weight of a carbonaceous material selected from a group consisting of natural graphite, synthetic graphite, carbon and coke;
• 4-20 percent by weight of glass fiber to provide strength for the friction pads;
• 36-60 percent by weight of inorganic friction modifiers selected from a group consisting of barytes, whiting, talc, rottenstone, verrniculite and suzorite mica to provide strength and friction stability for the friction pads;
• 2-12 percent by weight of an abrasive particle selected from a group consisting of silica, magnesia, zircon, zirconia, mullite, alumina, and iron oxides for developing a desired level for the coefficient of friction and a degree of friction stability necessary for the friction pads;
• - 8percent by weight of a lubricant material selected from a group consisting of molybdenum sulfide, calcium fluoride, antimony trisulfide, and cryolite;
• and
• 2-18 percent by weight of porous copper powder, said porous copper powder assisting in the formation of the glaze to reduce wear between the aluminum rotor and friction pads during a brake application.