Friday, February 27, 2009 3:00 – 4:00 pm
Room 610, M&M Building
Chassis Materials Technical Leader
Ford Research and Advanced Engineering
Ford Motor Company
Failure mode avoidance is a product development strategy at Ford Motor Company todeliver improved vehicle performance. The root cause of customer perceived failuremodes such as brake wear, dust, and vibration are analyzed and individual materialscountermeasures are discussed. The high-level environmental impact of theseindependent countermeasures is noted.After this “component-level” approach, a system-level solution will be presented thataddresses the same failure modes. This system approach will require rotor substrateand wear-layer materials development. Through a detailed understanding of the systemperformance, the materials requirements can be clearly defined. In the case of the rotorsubstrate, the material must have > 10 MPa yield strength and < 10-5/s creep rate at ≈500°C. The low stress and time at temperature (< 1 hr lifetime) may enable the design ofa high-temperature aluminum alloy for the rotor structure. The friction wear layer musthave similar tribological behavior to the baseline cast iron in addition to matching thermalexpansion and galvanic potential of the aluminum substrate. General corrosionresistance will significantly reduce rotor and lining wear. This materials-system solutionwill facilitate a lightweight, “lifetime” brake rotor that reduces use-phase environmentalimpact.