Noisy brakes are already the number one cause of complaint, and warranty claims, from car owners. And with next generation brake design requiring new materials to deal with extremes of temperature, load and speed, it’s never been more important to address the triple threat of noise, vibration and harshness (NVH). Presented as part of the renown SAE International webinar series, Dow Corning thought leader Gary Weber discusses the NVH issues emerging through innovation in brake design and the lubricants that can solve them. Discover real-life application examples and experimental evidence, as well as specific techniques for damping, isolation and absorption. Discover the smart specialty brake lubricants that are reducing brake drag and rolling, increasing the service life of components and providing effective barriers against chemical, mechanical, thermal and electrical stress. And if you found this presentation useful, don’t forget to share it and join the discussion below.

1. SAE INTERNATIONAL
Smart NVH Solutions for
Next-Generation Brake Design
Gary Weber
Application Engineering & Technical Service
Molykote® brand Specialty Lubricants from Dow Corning

2. Discussion Outline
• Evolution of Automotive Brake Systems
• Next-Generation Design Trends and Challenges
• Tribological Lubrication Regimes
• Range of Smart Lubrication™ Solutions
• Examples of Smart NVH Solutions for Brakes
• Proactive Design to Minimize Brake NVH
• Q & A
2

3. Evolution of Automotive Brake Systems
3
• Reducing residual brake drag
• Regenerative braking
• Stop-start systems braking
• Autonomous emergency braking (AEB)
Next-generation design
trends and challenges
Drum brake
and mechanical
parking brake
Caliper is introduced
and parking brake is
integrated into drum brake
Proliferation
of electronics into
braking system

4. Smart Science Drives Mobility Innovation™
4
Energy Efficiency
Connectivity & Safety
Comfort & Design
Eliminate/reduce NVH
Material & temperature capability
Vehicle system longevity
Brake performance
Fuel economy/efficiency
Lightweighting
Legislative & consumer pull
Brake by wire
Autonomous emergency braking
Reduce brake drag and rolling
resistance
Meet or exceed regulatory limits on
solvents and additives
Ensure compatibility with different
design materials – elastomers,
plastics and metals
Provide “lifetime” lubrication solutions
for controlling noise, vibration and
harshness
Improve component service life and
reliability with optimized friction-
control
Enhance lubricant resistance to
chemical, mechanical, thermal and
electrical stresses
Improve resistance to extreme heat,
corrosion and oxidation
TRENDS INDUSTRY FOCUS BRAKE NVH LUBRICANTS

5. • LINKING TRENDS
TO TRIBOLOGY

6. Using Tribology to Solve Brake NVH
OEM/Supplier Design Needs:
• Brake NVH performance is critical for:
− Improving user experience (UX)
− Reducing vehicle warranty claims
Smart Solutions:
• Tribology (study of friction, wear
and lubrication) identifies different
lubrication regimes for addressing
brake NVH performance – from the
pedal to the pad
• Stribeck Curve – basis of tribology
6

7. Tribological Lubrication Regimes
7
Asperity Friction
Hydrodynamic
Friction
Greases
Fluids/oils
FrictionCoefficient
Total Friction
Film Friction
Hydrodynamic
Lubrication
(3 ≤ λ)
Brake System
Lubrication
3
Boundary Friction
Solid lubes
Pastes
AFCs
Mixed Friction
Greases w/solids
Dispersions
Boundary
Lubrication
(0 ≤ λ ≤ 1)
Mixed Lubrication
(1 ≤ λ ≤ 3)
STRIBECK CURVE
1 2

8. Specialty Lubricant Solutions
8
Greases
Pastes
Oils
Compounds
Dispersions
Anti-Friction
Coatings
Lubricating
fluid,
thickening
agent,
additives
Grease-like
with high
percentage
of solid
lubricants
Lubricating
fluids with
specialty
additives
Grease-like
silicone
fluids with
silica filler
Finely
dispersed
solids in
lubricating
fluids
“Lubricating
paints”; cure
to form dry,
solid lubricant
coatings bonded
to the surface

9. Using Tribology to Reduce Brake NVH
• Breaking down NVH
− Noise  acoustics
− Vibration  transmitted feel
− Harshness  sound quality and occupant perception
• Approach for NVH reduction
− Damping – allow smooth and consistent operation
− Isolation – prevent fretting, stick-slip, seizure
− Absorption – materials of construction, material compatibility
• What is the smart way to tackle surface engineering and
tribology issues related to brake system NVH?
− With specialty lubricants
9

10. Specialty Lubricants Aid
in Smart Brake Design
• Greases provide damping to allow smooth and consistent
operation and performance at temperature extremes
• Solid lubricants create isolation between contacting surfaces to
prevent stick-slip, seizure and corrosion
• Compounds act as absorption mediums to interrupt the sound
path from source to receiver
− Materials of construction and material compatibility are key
considerations
10

11. Greases as Smart NVH Solutions for Brakes
Guide Pin Lubrication Requirements
• Eliminate fretting corrosion, sticking and binding
• Reduce excessive pin wear causing noise and
operation issues
• Prevent high-temperature seizure and reduced
braking power
Proven, Effective Solutions
• Silicone or PAG (polyalkylene glycol) greases
‒ Rubber/metal and metal/metal pairings
‒ Elastomer compatibility at elevated temperatures
(150ºC)
‒ Low frictional force
‒ Good compatibility with brake fluids
11
0 5 10
Time, min
0
20
40
60
80
100
Force,N
Silicone with MoS2
Molykote® G-3407
Caliper Pin Grease
Silicone
with PTFE

12. Greases as Smart NVH Solutions for Brakes
Electric Parking Brake
• Lubrication of polymer gear sets
‒ Multiple gear reductions
• Material compatibility is key – brake fluid, polymer,
elastomer
• Dielectric capability
Proven, Effective Solutions
• PAO and PAG (polyalkylene glycol) greases
‒ Polymer/metal and polymer/polymer pairings
‒ Performance over entire lubrication regime
‒ Low frictional force; high-pressure performance
‒ DOT3 and DOT4 brake fluid compatible
12

13. Molykote® G-1074 Grease:
A Noise-Damping EP Grease
13
30% reduction in noise versus
competitive offering
Extreme-pressure capabilities and noise-damping
abilities allow Molykote® G-1074 Grease to excel
in high-speed polymer-based gear trains.
Property tested, unit Competitor A Competitor B Molykote® G-1074 Grease
OK load, N 300; 200; 100 500; 600; 800 1,000; 1,000; 900
Temperature: 50˚C;
stroke: 1 mm;
frequency: 50 Hz; test
ball: SUJ-2; test disk:
SUJ-2, procedure A
*Data variations are acceptable based on ASTM D5706, #11. Precision and Bias. Repeatability is less
than 0.7X at 95% probability, where X = the average of two results, N.
Molykote® G-
1074 Grease has
much greater
extreme-pressure
value than
Competitors A
and B.*
Molykote® G-
1074 Grease
Competitor A Competitor B
SRV extreme-pressure test results – ASTM D5706
Noise test results vs. Competitor A
Molykote® G-1074 Grease
Competitor A
Property tested, unit
Molykote® G-1074
Grease
Competitor A
Average noise, dB 50.2 53.3

14. Smart NVH Solutions for Shims and Clips
Brake Shims and Abutment
Clip Coatings
• Travel path for brake noise
• Reduce and control friction and wear
• Ensure quiet and consistent pad
movement
Proven, Effective Solutions
• Solid lubricants of pastes and anti-friction
coatings
‒ Performance over wide temperature range
‒ Noise-damping and vibration absorption
capacity
‒ Minimizing vibrations due to DTV
‒ Excellent corrosion protection
14
Coefficient of friction
36 N load and 10 Hz
TIME, SECONDS

15. Molykote® D-709 Anti-Friction Coating:
Next-Generation NVH Coating
15
• Molykote® D-709 Anti-Friction Coating
exhibits 3x wear life versus Molykote® D-708
Anti-Friction Coating
• Greater wear resistance and lower CoF than
competitive offerings
• Silver color to minimize appearance of
coating scratches
TEST CONDITIONS
Load: 9.8 N
Stroke: 4 mm
Speed: 100 osc/min
Ball: 1/2 inch SUJ2 steel
Test temperature:
Room temperature
LOAD
AF
COATING
SUS #304
PLATE
Lubricity (oscillation test)
Molykote® D-708 Anti-Friction Coating
Competitor A
Molykote® D-709 Anti-Friction Coating
Cross-cut test
Molykote® D-708
Anti-Friction Coating
Molykote® D-709
Anti-Friction Coating
Scratch markScratch mark

16. Considerations for Proactive Design to Minimize
Brake NVH
• Vehicle cabin continually becoming quieter
• Innovative materials bring new tribological challenges
• Materials of construction are KEY in system design
− Lightweight alloys; fibers and composites
• Root causes of unacceptable brake NVH include inadequate
lubrication, high friction or excessive wear
• Temperature, load, speed – all reaching new extremes
− Lubricant solution needs to be compatible with all materials
Specialty lubricants – smart, effective solutions for
approaching next-generation design
16

17. Questions?
BOOTH 431
SEPTEMBER 25-28
The Westin Kierland
Resort & Spa
Scottsdale, Arizona

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