Abstract: Friction material pads for use in a brake system with an aluminum-metal matrix composite rotor wherein a brake application can create operational temperatures that approach 450C. The formulation of the composition for the friction pads is generically a basic non-asbestos organic formula modified to include a high abrasive content, solid lubricant package, and a porous copper powder. The porous copper powder which makes up from 2-18 percent by weight the friction pads has a nominal diameter of 0.20 mm. The porous copper powder proportionally responds to temperature and mechanical forces generated during a brake application by deforming and smearing to aid in the formation of a glaze between the engaging surfaces of the friction pads and aluminum-metal matrix composite rotor. This glaze prevents scoring of the aluminum-based rotor while at the same time maintaining a substantial stable coefficient of friction of approximately 0.4 during brake applications over a wide range of speeds and deceleration rates.

Abstract: A composition for a friction material for use in vehicle brakes wherein a lignin substance is substituted for a portion of the phenolic resin binder normally used in the friction material to thereby produce a substantially uniform coefficient of friction over the normal thermal operational range of such brakes.

Abstract: A high carbon friction material for use as a friction lining in a brake or clutch. The friction material consists of a combination of fibers selected from a group including glass, asbestos or other mineral fibers, metal powders, friction modifiers and carbon or graphite particles retained in a matrix created by a thermoset phenolic resin to establish a friction lining. The selected fibers and carbon or graphite particles in the friction material jointly combine to establish a substantially uniform wear rate and coefficient of friction up to 500.degree. C. when the friction lining engages a corresponding mating surface.