Molded Vs. Sintered Friction Material: Know the Difference

The global market for friction materials is projected to hit $23 billion by 2020. So are you looking to differentiating molded vs. sintered friction material? This article is a guide to understanding each of these two materials.

With asbestos ruled out as a friction material in many countries, there has been ongoing research for alternatives. These two materials are among the most prevalent in the market today.

What Is Molded Friction Material?

Molded frictional materials are made through molding metals through a hydraulic pressing method.

The process of molding the frictional material includes the following;

  • Blending vermiculite particles, asbestos-free filler, and thermosetting resin
  • Placing the blended mixture into a shaped mold cavity
  • Compressing the mixture at high pressure and room temperature to form a preform
  • Hot-pressing the preform into a different mold at a temperature of about 350oF and 2500 psi

It requires the right equipment, materials, and personnel to manufacture quality products.

Application of Molded Friction Material

Molded friction materials are used in heavy machinery such as cranes, lift trucks, mining and logging equipment, draglines, and shovels. Generally, they are appropriate for heavy industrial application. For high-performance cars, they are ideal because they can withstand very high levels of heat.

What Is Sintered Friction Material?

Sintered frictional materials are made through metal metallurgy. A sintered material can come from any of these materials;

  • Nickel
  • Steel
  • Brass
  • Copper
  • Bronze
  • Aluminum

The powder is mainly formed using the atomization process. It is then taken through the process of metallurgy to manufacture friction materials.

The sintering process maintains the physical attributes of the metal.

The powder is poured into a mold or die cavity as per the shape of the desired part. It’s then compacted under high pressure at room temperature to form a solid shape.

The solid part is then placed in a furnace and heated under extreme heat. This is the sintering process, which fuses the metal particles to form a rigid product.

This process is used to manufacture clutches, brake pads, and brake linings.

Application of Sintered Friction Material

Compared to molded materials, the sintered ones have more frictional characteristics. They can be used in regular cars to heavy industrial machinery. Besides, they are inexpensive hence popular among many.

The Durability of Molded Vs. Sintered Friction Material

Sintered materials have a higher friction coefficient than the molded ones. However, both types of brake systems have high durability. It all depends on usage.

The mixture of elements gives sintered frictional material lots of friction. Also, the molded ones tolerate high temperatures while maintaining grip.

Choosing Between Molded and Sintered Frictional Materials

Selecting quality materials can be difficult. However, it’s still easy to choose the ideal one.

Molded materials function better in cold conditions while the sintered counterparts are ideal for warm conditions. Sintered ones wear down the rotor unlike the molded one. With both products being long-lasting, the ultimate decision lies with the user.

The Bottom Line

Deciding between molded vs. sintered friction material? Both of them will serve you as long as you purchase from quality manufacturers. Visit our site and access more quality industrial products.

Posted in Industrial Equipment.