Brake Lining - Structure and Function

Structure and Function

Brake linings are composed of a relatively soft but tough and heat-resistant material with a high coefficient of dynamic friction (and ideally an identical coefficient of static friction) typically mounted to a solid metal backing using high-temperature adhesives or rivets. The complete assembly (including lining and backing) is then often called a brake pad or brake shoe. The dynamic friction coefficient "µ" for most standard brake pads is usually in the range of 0.35 to 0.42. This means that a force of 1000 Newtons (or pounds) on the pad will give a resulting brake force close to 400 Newtons (or pounds). There are some racing pads that have a very high µ of 0.55 to 0.62 with excellent high temperature behaviour. These pads have high iron content and will usually outperform any other pad used with iron discs. Unfortunately nothing comes for free, and these high µ pads wear fast and also wear down the discs at a rather fast rate. However they are a very cost effective alternative to more exotic/expensive materials.

Using a typical bicycle brake as an example, the backing would be the metal shell which provides mechanical support, and the lining would be the rubbery portion which contacts the rims when the brakes are applied. In most modern vehicular applications the system is conceptually identical, except the rims would be replaced with solid steel (or sometimes exotic metal) disc. Furthermore, a metal tang is usually incorporated into the pad assembly. The tang contacts the rotors when the linings are worn out, causing an annoying noise designed to alert the motorist that brake servicing is required.

Since the lining is the portion of the braking system which converts the vehicle's kinetic energy into heat, the lining must be capable of surviving high temperatures without excessive wear (leading to frequent replacement) or outgassing (which causes brake fade, a decrease in the stopping power of the brake).

Due to its efficacy, chrysotile asbestos was often a component in brake linings. However, studies such as a 1989 National Institutes of Health item showed an uncommonly high proportion of brake mechanics were afflicted with pleural and peritoneal mesothelioma, both of which are linked to chrysotile and asbestos exposure. Public health authorities generally recommend against inhaling brake dust, chrysotile has been banned in many developed countries, such as Australia in late 2003, and Chrysotile has been progressively replaced in most brake linings and pads by other fibers such as the synthetic aramids.