**Meet the editor**

Professor Dr. Katsuyoshi Kondoh is a vice director of Joining and Welding Research Institute (JWRI), Osaka University. He received both B.S./M.S. degrees and PhD from Osaka University majoring in arc welding process. His major research field is powder metallurgy materials and processing, in particular non-ferrous materials and their composites such as magnesium, titanium, alumi-

num and copper. He also studies on high-performance carbon nanotubes reinforced metal matrix composites and CNTs coating process for mechanical materials and biomaterials. He published more than 200 papers and has about 120 patents.

Contents

**Preface VII** 

Andrew Kennedy

Burcu Ertuğ

Chapter 1 **Selection of Best Formulation for Semi-Metallic Brake Friction Materials Development 1** 

Isabel Duarte and Mónica Oliveira

Chapter 4 **The Fabrication of Porous Barium Titanate** 

Talib Ria Jaafar, Mohmad Soib Selamat and Ramlan Kasiran

Chapter 2 **Porous Metals and Metal Foams Made from Powders 31** 

Chapter 3 **Aluminium Alloy Foams: Production and Properties 47** 

**Ceramics via Pore-Forming Agents (PFAs) for Thermistor and Sensor Applications 73** 

Chapter 5 **Hybrid Gas Atomization for Powder Production 99**  Udo Fritsching and Volker Uhlenwinkel

## Contents

#### **Preface XI**


Udo Fritsching and Volker Uhlenwinkel

Preface

From high-performance, economical and environmental points of view, *Powder metallurgy* process shows remarkable advantages in production of parts and components due to their special compositions by elemental mixing and 3-dimensional near net shape forming methods. Powder metallurgy process can be applied to not only metal materials but also ceramics and organic materials, which both are employed as structural and electrical products. Author contributions to *Powder metallurgy* present excellent and significantly important research topics to evaluate various properties and performance of P/M materials for applying these materials as actual components. In particular, the life estimation of P/M ferrous materials by sliding contact fatigue test and tribological performance evaluation of P/M semi-

**Katsuyoshi Kondoh**

Osaka University

Japan

Joining and Welding Research Institute (JWRI)

metallic materials are focused and introduced in this book.

## Preface

From high-performance, economical and environmental points of view, *Powder metallurgy* process shows remarkable advantages in production of parts and components due to their special compositions by elemental mixing and 3-dimensional near net shape forming methods. Powder metallurgy process can be applied to not only metal materials but also ceramics and organic materials, which both are employed as structural and electrical products. Author contributions to *Powder metallurgy* present excellent and significantly important research topics to evaluate various properties and performance of P/M materials for applying these materials as actual components. In particular, the life estimation of P/M ferrous materials by sliding contact fatigue test and tribological performance evaluation of P/M semimetallic materials are focused and introduced in this book.

> **Katsuyoshi Kondoh** Joining and Welding Research Institute (JWRI) Osaka University Japan

**1** 

*Malaysia* 

*Kulim Hi-Tech Park, Kulim,* 

**Selection of Best Formulation for Semi-Metallic** 

Brake friction materials play an important role in braking system. They convert the kinetic energy of a moving car to thermal energy by friction during braking process. The ideal brake friction material should have constant coefficient of friction under various operating conditions such as applied loads, temperature, speeds, mode of braking and in dry or wet conditions so as to maintain the braking characteristics of a vehicle. Besides, it should also posses various desirable properties such as resistance to heat, water and oil, has low wear rate and high thermal stability, exhibits low noise, and does not damage the brake disc. However, it is practically impossible to have all these desired properties. Therefore, some requirements have to be compromised in order to achieve some other requirements. In general, each formulation of friction material has its own unique frictional behaviours and

Friction material is a heterogeneous material and is composed of a few elements and each element has its own function such as to improve friction property at low and high temperature, increase strength and rigidity, prolong life, reduce porosity, and reduce noise. Changes in element types or weight percentage of the elements in the formulation may change the physical, mechanical and chemical properties of the brake friction materials to be developed (Lu, 2006; Cho et Al., 2005; Mutlu et al., 2006 & Jang et al., 2004). Earlier researchers have concluded that there is no simple correlation between friction and wear properties of a friction material with the physical and mechanical properties (Tanaka et al., 1973; Todorovic, 1987; Hsu et al. 1997 & Talib et. al, 2006). Therefore, each new formulation developed needs to be subjected to a series of tests to evaluate its friction and wear properties using brake dynamometer as well as on-road braking performance test to ensure that the brake friction material developed will comply with the minimum requirements of

Two major types of brake dynamometers are commonly used to evaluate the friction and wear characteristics of the friction materials are the inertia dynamometer and CHASE dynamometer. Inertia dynamometer is used to evaluate a full size brake lining material or brake system by simulating vehicles braking process but it is time consuming and more

**1. Introduction** 

wear-resistance characteristics.

its intended application.

**Brake Friction Materials Development** 

*1Advanced Materials Centre, SIRIM Berhad, 34, Jalan Hi-Tech 2/3,* 

Talib Ria Jaafar1, Mohmad Soib Selamat1 and Ramlan Kasiran2

*2Faculty of Mechanical Engineering, University Technology MARA, ShahAlam* 
