Introduction of Cu-free material LC02A

Report # 1303003
March. 26, 2013
Advanced functional materials R&D Dept.

Confidential
Hitachi Chemical Co., Ltd. 2012. All rights reserved.
Concept of Cu-free NAO material
1/13

Cu-Free material LC02A is superior to N507H on pad life and NVH property.
Hitachi Chemical recommends this material to improve CS in NA market.
AKM
V120
Copper AKM LC02A Characteristics
contents Fade1
(wt%)
1. Eco-friendliness
J201 Cu < 0.5wt%, Sb Free
2. Long pad life
Creep Rotor
groan wear Low pad wear under high temperature
3. Good creep groan property
N507H Small Stick-Slip vibration

Pad wear 4. Good aging judder

Noise
100oC Low rotor wear during off-braking
Pad wear
400oC LC02A
Hitachi Chemical Co., Ltd. 2012. All rights reserved.
Test condition Confidential 2/13

Brake System Data

Passat brake unit HC benchmark unit

Rotor : 312X25 Pad Area : 60.0cm2 Rotor : 296X24 Pad Area : 51.7cm2
Inertia : 80.0 kgm2 Eff. Radius : 0.128m Inertia : 68.8 kgm2 Eff. Radius : 0.123m
Rolling Radius : 0.308m Rolling Radius : 0.323m
Energy loading : 884 Nm/cm2 sec Energy loading : 686 Nm/cm2 sec
(100km/h, 0.6G) (100km/h, 0.6G)

Test item
Friction Material NAO LS
Test code Brake unit LC02A N507H J201

AK Master SAE J2522 Passat

Wear JASO C427 HC benchmark

Dyno test
Noise SAE J2521 Passat

Creep groan HC code Passat

Low pressure rotor wear HC code Test piece

Hitachi Chemical Co., Ltd. 2012. All rights reserved.
AK Master (SAE J2522 / Passat unit) Confidential 3/13

LC02A has good stability in comparison between before and after heat fade.
LC02A is better than N507H on the level of high speed section.
vmax (200170km/h) : N507H < J201 LC02A
MW2 (225125km/h) : N507H < LC02A < J201
0.5

0.4
value

0.3

0.2
N507H
0.1 J201
LC02A
0.0
T500

min
op6

op6

MW2
vmax
v120

F1

F2
Fade min-min

nom
op18

op18

op18
T40

Hitachi Chemical Co., Ltd. 2012. All rights reserved.

 Wear (JASO C427 / Hitachi benchmark unit) Confidential 4/13

LC02A is better than N507H on pad wear under high brake temperature.

0.6 45
LC02A LC02A

Rotor wear (m /1000 braking)

40
Pad wear (mm /1000 braking)

0.5 N507H N507H

J201 35 J201
0.4 30
25
0.3
20
0.2 15
10
0.1
5
0.0 0
0 100 200 300 400 500 0 100 200 300 400 500
Brake temperature (oC) Brake temperature (oC)

Hitachi Chemical Co., Ltd. 2012. All rights reserved.

Noise (SAE J2521 / Passat unit) Confidential 5/13

LC02A is better than N507H and J201 on noise performance.

Material LC02A N507H J201

> 70dB 0 0.42 0.14

Squeal noise 0 0 0
> 80dB
occurrence (%)
> 90dB 0 0 0

Max Sound Pressure (dB) - 74.7 75.6

Frequency (kHz) - 2.6 2.9 1.7

Low frequency noise
(Grant noise / Not squeal) 0 0.07 1.89
Occurrence (%)
Note : Noise evaluation sections; section 1 to section 18

Hitachi Chemical Co., Ltd. 2012. All rights reserved.

Creep groan (HC code / Passat unit) Confidential 6/13

We evaluated the creep groan property by using

Creep torque / one wheel
dyno tester with torque arm. Air force =
Length of torque arm L

1. Apply the brake using 20bars caliper line L

pressure.
Caliper

2. Apply the creep torque (300Nm) to the

rotation shaft by using air cylinder.

Air force

3. While recording torque and pressure,

release the brake pressure at 2bar/s.
Air cylinder
Rotor

Fig. 1 Test equipment

Hitachi Chemical Co., Ltd. 2012. All rights reserved.

 Creep groan (HC code / Passat unit) Confidential 7/13
350
Stick-Slip Torque
To measure the creep groan property by using dyno tester,
we evaluated two parameters below;
300
1. Static-Dynamic Mu ratio S-D/s
The larger value indicated, the louder creep groan noise occurs.
Torque [Nm]

250

2. Time of the stick-slip vibration

The longer value indicated, the lengthier creep groan noise occurs.
200

Expansion 350 = 142msec

150
Torque
Stick Slip

100 300
11000 13500 16000
Time [msec]
Torque [Nm]
250

S : Static Mu
Static-Dynamic Mu ratio 200 (Calculated by the torque at the
stick situation )

S-D/s = S - D
D : Dynamic Mu
S 150 (Calculated by the average
torque at slip situation )
= Damping time of the stick-slip Frequency : 166Hz
vibration 100
13100 13150 13200 13250 13300
Time [msec]
Hitachi Chemical Co., Ltd. 2012. All rights reserved.
Creep groan (HC code / Passat unit) Confidential 8/13

We evaluated static-dynamic Mu at the three conditions ( RT/Dry, Cold/Dry and Cold/Wet ).

Braking condition
Measurement of
No. Section Deceleration Braking Nr. Static-Dynamic Mu
V (km/h) IBT (oC) (g) (times)

1 Burnish (20oC, 50%RH) 600 100 0.3 250 -

2 Static/Dynamic Mu check (RT/Dry) - Ambient - -

3 Re-burnish (20oC, 50%RH) 600 100 0.3 30 -

Change the environment (0oC)

4 Static/Dynamic Mu check (Cold/Dry) - 10 - -

5 Cold re-burnish (0oC) 600 100 0.3 30 -

Water spray standing ( 0oC, 5 hour)

6 Static/Dynamic Mu check (Cold/Wet) - 0 - -

Hitachi Chemical Co., Ltd. 2012. All rights reserved.

 Creep groan (HC code / Passat unit) Confidential 9/13
[ Typical waveform during stick-slip vibration/ RT/Dry ]

J201
350
=225[msec]
In terms of the amplitude and the 300

Torque [Nm]
damping time of stick-slip vibration, 250
LC02A has an advantage on
200
creep groan phenomenon.
150
f=200Hz

100
11150 11200 11250 11300 11350 11400 11450

Time [msec]
350 LC02A 350 N507H
=58[msec] =142[msec]

300 300
Torque [Nm]

Torque [Nm]
250 250

200 200

f=200Hz
150 150
f=167Hz
100 100
6450 6500 6550 6600 6650 6700 6750 13000 13050 13100 13150 13200 13250 13300
Time [msec] Time [msec]
Hitachi Chemical Co., Ltd. 2012. All rights reserved.
Creep groan (HC code / Passat unit) Confidential 10/13

LC02A is better than N507H and J201 from the viewpoint of

Static-Dynamic Mu ratio and damping time during stick-slip vibration.

0.25
Material LC02A J201 N507H
: RT/Dry

Static Dynamic Mu ratio

: Cold/Dry : Cold/Wet
(sec) 0.05 1.28 0.14 0.20
RT/Dry
S-D/s 0.07 0.13 0.22 N507H
0.15

(sec) 0.04 1.08 0.11

Cold/Dry 0.10
S-D/s 0.04 0.10 0.19 J201
0.05
(sec) 0.02 0.05 0.03
Cold/Wet LC02A
S-D/s 0.03 0.07 0.06 0.00
0 0.5 1 1.5
(sec)

Hitachi Chemical Co., Ltd. 2012. All rights reserved.

Low pressure rotor wear (HC code / Test piece) Confidential 11/13

LC02A is better than N507H on low pressure rotor wear.

LC02A has an advantage for aging judder caused by DTV generation.
100
21.4
rotor wear (m)
Low pressure

Typical low-steel : 9.2 - 35.0 m

10
1.6
1 Typical NAO : 0.2 3.0 m
0.2
0.1
LC02A N507H J201
[ Test method ] Low pressure rotor wear
= (Avg. profile pre test) (Avg. profile post test)
Pressure 73.4kPa

After
Test
22hr
piece Rotation
(1inch) (14.5m/s) Hitachi Chemical Co., Ltd. 2012. All rights reserved.
Conclusion Confidential 12/13

Cu-Free material LC02A has advantages on high speed effectiveness,

NVH performance and high temperature pad wear.

Material LC02A N507H J201

v120 0.33 0.32 0.35
AK Master MW2 0.27 0.22 0.37
(SAE J2521) F1 (Fade1min) 0.28 0.29 0.33
F2 (Fade2min) 0.34 0.32 0.37

Passat Brake unit Noise >70dB squeal occurrence(%) 0 0.42 0.14

(SAE J2522) Max sound pressure (dBA) - 75 76
Section1-18 Low frequency noise (%) 0 0.07 1.89
Creep groan S-D/s 0.07 0.22 0.13
Static-dynamic
(RT/Dry) (sec) 0.05 0.14 1.28

HC benchmark Pad wear 100o C 0.11 0.12 0.18

brake unit (mm/1000braking) 400o C 0.28 0.44 0.3
Test piece Aging judder / Low pressure rotor wear (m) 0.2 1.6 21.4
Hitachi Chemical Co., Ltd. 2012. All rights reserved.
Line-up and application status of Hitachi Chemicals
Cu-reduced NAO materials Confidential 13/13

HCs Cu/Sb-free NAO line-up consists of two product families.

HC is planning to bring out LC series for some application programs.

[ Line-up of Cu-reduced NAO materials ]

AR series LC series
Green Cu < 5% < 0.5%
level Sb Non Non
Concept Good fade property Long pad life, Good NVH

Development progress Under development Evaluation for application program

[ Application status of LC series ]

Carmaker Vehicle SOP
Midsize Sdn 2014
A
Premium compact car 2015
Entry Luxury SUV 2015
B
Premium compact car 2015
Hitachi Chemical Co., Ltd. 2012. All rights reserved.
Introduction of Cu-free Low cost material H21
Characteristics of LC02A & H21
Effectiveness

Cost Heat Fade

H21 SK66K
Cu free / Low cost
Excellent Mu stability
Green
Pad life

LC02A
Cu free / long pad life
Squeal noise Judder
(Cold)
Squeal noise
(Hot)

LC02A H21 SK66K

Copper contents < 0.5% < 0.5% < 5%
Antimony compounds Non Contain Contain
Hitachi Chemical Co., Ltd. 2012. All rights reserved.