MIOX as a functional filler for Brake Pads

© 2020 Kärntner Montanindustrie GmbH 1MIOX in Brake Pads rev01 EN

MIOX® as a functional filler for Brake PadsA COST EFFICIENT AND HIGH QUALITY RAW MATERIAL FOR BRAKE PADS

© 2020 Kärntner Montanindustrie GmbH MIOX in Brakes Pads rev 01 EN


The Company

Kärntner Montanindustrie (KMI) is an Austrian company,founded in 1932. The company owns Micaceous Iron Oxidemines and mineral processing facilities.

The headquarter is in the castle of Wolfsberg, the regionalcapital. The mine and processing plant are located not farfrom that in Waldenstein, both in the State of Carinthia.


The Waldenstein Mine

KMI‘s mine at Waldenstein is

a well-known source of Micaceous Iron Oxide (MIO)

with characteristic lamellar structure and high purity.

The reserves are sufficient for the next decades. The mine is anunderground operation, which enables an all-seasonexcavation.


The Mineral

Waldenstein ore contains anatural iron oxide (Fe2O3)which distinguishes it fromother iron ores with itsmetallic grey lustre.

Its lamellar structure – resembling that of mica – has also given it its name:

Micaceous Iron Oxide (MIO)


The Processing Plant

KMI‘s processing plant is

in vicinity to the MIO mine.

The crude ore is sorted, sieved and classified by specialtechniques. Through continuous development of thebeneficiation know-how, the distinguish lamellar structureof the MIO-grades is secured – independent from fineness.


KMI – an Expert in Micronization

KMI has long-term expertise in

delamination of minerals. Further

Investments in state-of-the-art grinding

technology enabled the micronization of Micaceous Iron Oxide.

These products are the finest on world markets.

Today, KMI is acknowledged as the world leader inMIO-technology, research and development.


Application Fields

Coatings

Heavy dutycorrosionprotection

Decorativemetal

protection

Partial replacementof Zinc-Dust

Thin film corrosionprotection

Powdercoatings

Coil coatings

Polymers

Automotive

Technical parts

Packaging

Building & construction

Furniture

Electrical & electronic

Ceramics

Tiles

Sanitaryware

FrictionMaterials

Brake pads forpassenger cars

Brake pads forcommercial

Brake pads formotor cycles

Brake pads forrail industry

Industrial Friction linings

Foundry

Veiningadditives

Coatingsadditives

BuildingMaterials

Fiber cement

Mortar

SpecialApplications

Weldingrods

Paper


MIOX® - the Brand of the Market Leader

MIOX® is the registered tradename of KMI for its micaceous iron oxide products.

For decades KMI has been renowned as worldwide leader inthe supply of iron ore pigments for anti-rust protectivecoatings.

Export rate of more than 95 %

Customers in more than 80 countries


Quality first

ISO 9001:2015 & ISO 14001:2015

Product quality, consistency andsupply reliability are the pillars ofKMI’s commitment.

KMI is aware of the stringent quality demands of theirinternational customers.

We are aware of the importance for the environment and thefuture of our children. KMI is committed to ensuring that allindustrial practices and products are socially, environmentallyand economically sustainable.


MIOX – Characterization and properties

Material: natural mineral

Mineralogy: Hematite,

naturally occurring

Chem. formula: Fe2O3 (Iron-III-Oxide)

Color: grey to reddish brown, metallic

Density: 4,8 g/cm³

Heat resistance: > 1100 °C / 2000 °F

Hardness: 6,0 – 6,5 MOHS mild abrasive

Lamellar shape: Micaceous Iron Oxide constant CoF


Raw materials for friction

Friction material

Fibers FillersFriction

modifiersResins

Promote structuralintegrity

Take up space. Contribute to

density. May be functional.

For friciton charcteristics &

level, durability and more

The glue that holdseverything together

e.g. steel fiber, aramid fiber, mineral fiber

e.g. Barites, CaCO3,

Mica, Wollastonite

e.g. friction dust,

graphite, copper

e.g. phenolic resin, sintered metal

MIOX®


Comparative Study in NAO – LamellarityComparison of lamellar and granular Iron Oxide

The objective of this comparative case study is the comparison of

high lamellar MIOX with granular Iron Oxide

and their influence on a copper-free NAO-formulation:

disk brake pads

copper-free NAO formulation

in comparison with granular Iron Oxide

tested by Produco GmbH, Schwarzenbek, Germany

TARGET: show influence of lamellarity


Comparative Study in NAO – LamellarityOverview Results

Lamellar (MIOX), granular Iron Oxide and Barytes with quartz were tested. Some trends are observable.

MIOX® is suitable for the use in the present copper-free NAO brake pad formulation

MIOX® provides a stable coefficient of friction due to its lamellarity

A high MIOX® content is preferable: It shows better results with 15 % than with 8 % content

MIOX® provides as high shearing strength as granular iron oxide and higher shearing strength than Barium Sulfate

Marginal differences in wear - in general low wear


Comparative Study in NAO – LamellarityTested Materials

Micaceous Iron Oxide

Granular Iron Oxide

Barytes with quartz

Particle Shape lamellar granular tabular

Mohs Hardness 6 - 6,5 5,5 - 6,5 3,5

Purity 92 % Fe2O3 98 % Fe3O4 90 % BaSO4

Median Particle Size d50 35 µm 20 µm 8 µm

Top Cut 100 µm 70 µm 50 µm

commonly used in brake pads


Comparative Study in NAO – LamellarityTested Materials - SEM


Granular Iron Oxide

80 % lamellar content 0 -10 % lamellar content


Comparative Study in NAO – LamellarityTested Materials – Light Microscopy


Granular Iron Oxide

80 % lamellar content 0 -10 % lamellar content


Comparative Study in NAO – LamellarityCopper-free NAO formulation

Testing FormulationMicaceous Iron Oxide


Granular Iron Oxide

Barytes withQuartz

[Vol-%] [Vol-%] [Vol-%] [Vol-%]

Filler 38.0 32.0 32.0 31.5

Friction stabilizer 16.5 17.0 17.0 17.0

Resin 9.0 9.5 9.5 9.5

Abrasive 12.0 12.0 12.0 12.0

Lubricant 2.5 2.5 2.5 2.5

Fibre 3.5 4.0 4.0 4.0

Grafite 14.5 15.0 15.0 14.5

Tested additive

Micaceous Iron Oxide 4.0 8.0

Granular Iron Oxide 8.0

Barium Sulfate 9.0

Total 100 100 100 100


Comparative Study in NAO – LamellarityTesting Procedure

Mixing of all raw materials

Papenmeier, vertical high speed mixer

batches of 2 kg for 4 min

Press curing under following conditions:

Pad type: Passenger car,

NAO brake pad

Pressure: 25 MPa

Temperature: 155 °C / 310 °F

Period: 30 s pressure, 15 s degassing,

30 s pressure, 15 s degassing,

210 s pressure


Comparative Study in NAO – LamellarityPerformed Tests and Testing Standards

Test Unit Testing standard or procedure

Pad shearing strength [N] ISO 6312

Specific shearing strength [kN/cm²] ISO 6312

Coefficient of friction µ - Dynamometer, AK-Master SAE J2522

Brake pad wear [g] after AK-Master SAE J2522

Disk wear [g] after AK-Master SAE J2522

Visual examination before and after AK-Master SAE J2522


Comparative Study in NAO – LamellarityCoefficient of Friction (AK-Master SAE J2522)

Higher MIOX content provides higher coefficient of friction

MIOX provides more friction stability than Barytes or granular Iron Oxide


Comparative Study in NAO – LamellarityCoefficient of Friction (AK-Master SAE J2522) )/Extract Fade 1

Extract from AK-Master: Fade 1


Comparative Study in NAO – LamellarityCoefficient of Friction (AK-Master SAE J2522) )/Extract Fade 2

15 % Barytes with Quartz

15 % MicaceousIron Oxide

15 % Granular Iron Oxide

Extract from AK-Master: Fade 2


5053

42

55

0

10

20

30

40

50

60

70

8 % Micaceous

Iron Oxide

15 % Micaceous

Iron Oxide

15 %

Barium Sulfate

15 % Granular

Iron Oxide

Sp

eci

fic

she

ari

ng

str

en

gth

[kN

/cm

²]

MIO provides higher specific shearing strength than Barium Sulfate

MIO provides as high shearing strength as granular iron oxide

Comparative Study in NAO – LamellaritySpecific Shearing Strength (ISO 6312)


Comparative Study in NAO – LamellarityDisk Wear (after AK-Master SAE J2522)

Similar disk wear with all types


Comparative Study in NAO – LamellarityBrake Pad Wear (after AK-Master SAE J2522)

Similar brake pad wear with all types


Comparative Study in NAO – LamellarityVisual Examination Disks (after AK-Master)



15 % Barium Sulfate

15 % granular Iron Oxide

Marginal differences: metallic bright, 1 black striation (outboard)


Comparative Study in NAO – LamellarityVisual Examination Disks (after AK-Master)



15 % Barium Sulfate

15 % granular Iron Oxide

Marginal differences: even surface, no metal pick-up


Comparative Study in Low-metallic – SubstitutionMIOX as a substitute for abrasives or friction modifiers

The objective of this comparative case study is the comparison ofMIOX to common and more expensive raw materials in a low-metallic formulation:

disk brake pads

low-metallic formulation

in comparison with an abrasive and a friction modifier

substitution of Zirconium Silicate (abrasive)

substitution of Potassium Titanate (friction modifier)

tested by Produco GmbH, Schwarzenbek, Germany

TARGET: achieve same quality and reduce cost


Comparative Study in Low-metallic – SubstitutionOverview Results

The comparative study has shown that MIOX can

partially replace

Zirconium Silicate (abrasive) and Potassium Titanate (friction stabilizer)

with consistent quality or even higher quality.

Cost-efficient raw material

Similar or improved NVH behavior

Reduced or similar wear

Moderate coefficient of friction

Increase of thermal transmission

Comparable compressibility

Similar physical characteristics

Similar processing behavior


Comparative Study in Low-metallic – SubstitutionLow-metallic formulation

Testing Formulation with 3 wt-% additive with 6 wt-% additive

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

[vol-%] [vol-%] [vol-%] [vol-%] [vol-%] [vol-%]

Metal 8.6 8.6 8.6 8.5 8.5 8.4

Filler 47.7 47.7 47.3 46.6 46.6 46.1

Lubricant 14.4 14.4 14.3 14.2 14.2 14.0

Organic Fibre 3.4 3.4 3.4 3.4 3.4 3.3

Abrasive 7.2 7.2 7.1 7.0 7.0 6.9

Resin 16.9 16.9 16.8 16.6 16.6 16.3

Tested additive

MIOX 1.8 3.7

Zirconium Silicate 1.8 3.7

Potassium Titanate 2.5 5.0

Total 100 100 100 100 100 100


Comparative Study in Low-metallic – SubstitutionTested Materials

MIOX – micaceous Iron Oxidemild abrasivehardness (MOHS) 6 – 6.5average particle size d50 = 35 µmparticle shape lamellar

Zirconium Silicateabrasivehardness (MOHS) 7.5average particle size d50 = 100 µm

Potassium Titanate (magnesium potassium titanium oxide)friction modifierhardness (MOHS) 4average particle size d50 = 6 – 10 µmparticle shape flaky


Comparative Study in Low-metallic – SubstitutionPerformed Tests and Testing Standards

Test Unit Testing standard or procedure

Bulk density [cm³/100g] 100 g sample, 250 ml measuring cylinder, 4 min mixing

Dust adhesion [%] 10 g material on 1mm Sieve, passing without vibration

Height increase of greencompact

[%] measurement after 24 h

Green strength [N]green compact is vertically strained with brass strip(10x2mm) to destruction

Pad shearing strength [N] ISO 6312

Specific shearing strength [N/cm²] ISO 6312

Compressibility (RT, 400 °C) [µm] ISO 6310 (RT, 400 °C / 750 °F)

Thermal transmission [°C] ISO 6310

Thermal expansion [µm] ISO 6310 (400 °C / 750 °F)

Coefficient of friction µ - Dynamometer, AK-Master SAE J2522

Brake pads wear [g] after AK-Master SAE J2522

Disks wear [g] after AK-Master SAE J2522

Visual examination before and after AK-Master SAE J2522

Noise behaviour Dynamometer, SAE J2521


Comparative Study in Low-metallic – SubstitutionThermal Transmission (ISO 6310)

206

199 199205

200 199

150

160

170

180

190

200

210

3 %MIO

3 %Zirconium

Silicate

3 %PotassiumTitanate

6 %MIO

6 %Zirconium

Silicate


Th

erm

al

Tra

nsm

issio

n[°

C]

Similar or higher thermal transmission with MIOX


Comparative Study in Low-metallic – SubstitutionDisks Wear (after AK-Master)

12,3

14,3

12,511,6

14,4

12,8

0,0

5,0

10,0

15,0

3 %MIO

3 %Zirconium

Silicate


6 %MIO

6 %Zirconium

Silicate


Dis

ks

we

ar

[g]

Similar or lower brake disks wear with MIOX assumed due to lamellarity


Comparative Study in Low-metallic – SubstitutionPads Wear (after AK-Master)

10,211,2

9,810,4

11,3 11,0

0,0

5,0

10,0

15,0

3 %MIO

3 %Zirconium

Silicate


6 %MIO

6 %Zirconium

Silicate


Bra

ke

pa

ds

we

ar

[g]

Similar brake pads wear with MIOX assumed due to lamellarity


Comparative Study in Low-metallic – SubstitutionVisual Examination Disks (after AK-Master)

MIOX Zirconium Silicate Potassium Titanate

few black striations, minor differences


Comparative Study in Low-metallic – SubstitutionVisual Examination Pads (after AK-Master)

MIOX Zirconium Silicate Potassium Titanate

closed, even surface, minor differences


Comparative Study in Low-metallic – SubstitutionCoefficient of Friction (AK-Master SAE J2522)

0,20

0,30

0,40

0,50

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Co

eff

icie

nt

of

fric

tio

n µ

µ conditions

3 %MIO

3 %Zirconium Silicate

3 %Potassium Titanate

Similar, slightly higher coefficient of friction with MIOX


Comparative Study in Low-metallic – SubstitutionCoefficient of Friction (AK-Master SAE J2522) – Finer MIOX Grades

Similar coefficients of friction

Finer types provide more stable coefficient of friction


Comparative Study in Low-metallic – SubstitutionNoise behavior *) – Noise Index (SAE J2521)

0102030405060708090

100

6 %MIO

6 %Zirconium Silicate

6 %Potassium Titanate

No

ise O

ccu

ren

ces [

%]

Performance of MIOX in between the compared products

*) only for comparison: no underlayer, no shims, no scorching


Comparative Study in Low-metallic – SubstitutionNoise behavior depending on temperature *) – Noise Index (SAE J2521)

Performance of MIOX in between the compared products

*) only for comparison: no underlayer, no shims, no scorching


Comparative Study in Low-metallic – SubstitutionCompressibility/Room temperature (ISO 6310)

123111 109

119129

102

0

50

100

150

3 %MIO

3 %Zirconium

Silicate


6 %MIO

6 %Zirconium

Silicate


Co

mp

ressib

ilit

y[µ

m]

at ro

om

tem

pera

ture

Similar compressibility at room temperature with MIOX


Comparative Study in Low-metallic – SubstitutionCompressibility at 400 °C (750 °F) (ISO 6310)

163 164

141151 153 160

0

20

40

60

80

100

120

140

160

180

3 %MIO

3 %Zirconium

Silicate


6 %MIO

6 %Zirconium

Silicate


Co

mp

ressib

ilit

y[µ

m]

at

40

0 °

C

Similar compressibility at 400 °C / 750 ° F with MIOX


Comparative Studies with MioxSummary

The comparative studies show that lamellar MIOX can be used as

a partial replacement product for certain abrasives or friction stabilizers.

acts as mild abrasive

provides a stable, moderately high coefficient of friction

lamellarity is important

improves NVH behaviour

increases thermal transmission

reduces wear

…


Further Products for Brake Pads and Friction Material

KMI is an expert in delamination and

micronization of industrial minerals. The

following product range offers products

with high aspect ratio HAR:

Wollastonite

Mica Phlogopite

Mica Muscovite

Talc


Wollastonite

Material: naturally occurring mineral

Shape: acicular (needle-like)

Chem. formula: CaSiO3

Color: white

Density: 2,8 g/cm³

Hardness: 5 Mohs

Characterisation: mild abrasive ( hardness)

functional filler ( acicular shape)

environmental-friendly and harmless


MICA Phlogopite HLP-series


Shape: platy

Chem. formula: KMg3[AlSi3O10(F,OH)2]

Color: beige to brown

Density: 2,8 g/cm³

Hardness: 2,5 Mohs

Characterisation: functional filler ( platy shape)



MICA Muscovite HLM-series


Shape: platy

Chem. formula: KAl2[AlSi3O10(F,OH)2]

Color: white to grey

Density: 2,8 g/cm³

Hardness: 2,5 Mohs




TALC Talmio-series


Shape: platy

Chem. formula: Mg3[Si4O10(OH)2]

Color: white

Density: 2,7 g/cm³

Hardness: 1 Mohs




KMI‘s Business Objective

Kärntner Montanindustrie wants to be seen byits customers as a synonym for productinnovation and customer orientation.

We always appreciate to work on newdevelopments together with our customers.

It is the company's objective to further extendits position as a major player and to developnew application fields and markets forfunctional industrial minerals.


Contact

Kärntner Montanindustrie GmbH

Schloss 1, 9400 Wolfsberg, AUSTRIA

T: +43 (4352) 54 5 35 - 0F: +43 (4352) 54 5 35 - 135

[email protected]

Documents

MIOX as a functional filler for Brake Pads