Abstract: A method and apparatus is provided for forming an in-mold cured brake pad (16). A mold (24) includes sidewalls (28) through which a window (24) made from a generally lossless material such as alumina is formed. Microwaves (42) are directed through the window (46) and into the die cavity (26) of the mold (24) to provide supplemental heating and thereby accelerate the manufacturing cycle time. The friction material composition is tuned by adding an effective quantity of titania or other suitable agent which has the advantage of moving the absorption band for the heat-curable material into the standard band (50) of the microwaves (42) produced by a low-cost magnetron (40), and also of self-regulating the absorption characteristics of the heat-curable material so as to reduce or eliminate the tendency to thermal runaway.

Abstract: An electrochemical machining (ECM) system for machining a workpiece includes a plurality of ECM stations. A first ECM station machines a first region of the workpiece. A second ECM station machines a second region of the workpiece separate from the first region. Additional ECM stations may also be utilized. Each ECM station includes a stationary electrode for delivering electric current for eroding material from the workpiece. Each ECM station also includes an ultrasonic transducer for determining a width of electrolyte between the stationary electrode and the workpiece. Machining of the workpiece in each ECM station is completed when the width of electrolyte reaches a predetermined width.