Friction material is riveted to both sides of the clutch disc one side touches the flywheel of the engine and the other side touches the friction surface of the pressure plate.
Common types of friction lining materials include woven, moulded, sintered metal, ceramic, carbon and Kevlar. Requirements for material and mating surface wear life, heat resistance, noise reduction, dust containment and selection of a material that will increase the lifespan and overall efficiency in your brake or clutch application. [1]
There are two types of friction facings or lining namely, moulded & woven. Moulded friction facings are preferred because they withstand greater pressure plate loading force without damage. Woven friction facings are used when additional cushioning action is needed for clutch engagement. Woven materials are softer, but they may not last as long as moulded materials.
Friction materials operate in high heat and pressure. For many years, asbestos was the most common material used in both clutch and brake linings. However, it is no longer used because inhaling tiny particles of asbestos causes lung damage. Today, clutch friction material may contain particles of cotton, brass, rope, and wire to prolong the life of the clutch disc and to provide torsional strength.
Intermediate friction plate are made of high carbon steel and the core plates are made from aluminum, steel, high temperature resistant plastics, or phenol resin based fiber depending on the design of the clutch. The friction material in wet type clutch is made in three types, rubber based, cork based, paper based and for dry clutch, resin and fiber based material is used. This friction material is lined on the core plates to generate the torque in the engine. There are different friction materials for different applications to enhance the quality and performance of the vehicle i.e. more mileage, more life, high pickup etc. [2]
Early clutches were made with weak clutch discs that would wear out after just a minimal amount of usage. But today we have clutch material that can withstand high friction, high heat, and the force of the pressure plate. In this article, we’ll run you through the best materials modern clutches are made with. [3]
Organic
Organic clutch discs are made with a combination of friction materials. Most commonly, they’re made with phenolic resins, metallic powders, and compounded rubber. This type of material comes in two forms: woven and molded. In woven organic clutch discs, fiberglass is woven into the discs, increasing their durability and longevity. This makes them superior to their molded counterparts even though molded discs are much more affordable. [3]
Heavy-Duty Organic
Heavy-duty organic clutch materials are the same except they’re with a more significant percentage of metallic components. This means they’re more heat resistant. They can withstand temperatures as high as 700 degrees Fahrenheit. However, when it comes to engagement smoothness, these clutch discs are identical to organic clutch discs. [3]
Ceramic
Ceramic clutch plates are, ironically, made with a combination of copper, iron, bronze, and silicon and graphite. Because of their metallic content, these discs can withstand a lot of friction and heat. This makes them ideal for race cars and other high-speed vehicles that need to engage and disengage from fast-moving flywheels. However, these discs are high-friction. This means that the engagement and disengagement of the clutch won’t always be very smooth. [3]
Kevlar
Kevlar clutch discs have two key benefits: they’re incredibly durable, and they always engage the flywheel smoothly. They last 2-3 times longer than clutch discs made of organic materials. These are the ideal choice for machines that require smooth, precise movement. Their only downside is that they have a long break-in period before they feel right. [3]
Feramic is essentially a heavy-duty version of ceramic clutch discs. Made of similar materials – steel, silicon, graphite, etc. – feramic has an extremely high amount of friction, so they’re best used for machines that require quick lock-up like racing or heavy-duty trucking. A subgroup of feramic clutch discs, carbotic clutch discs, are very commonly used in trucking because they have smoother engagement while retaining strong heat resistance. [3]
Next Article: "Types of Clutches"
References:
[1] https://www.phoenixfriction.com/t-clutch-materials-explained.aspx
[2] https://www.mkautoindia.com/clutch-plate-and-clutch-facings.html
[3] https://kor-pak.com/best-clutch-material-friction/
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