Iron powders that put the brakes on noise, cost and wear

Understanding the advantages of ferrous powders in friction material brake pad formulations is key to developing stronger and more sustainable solutions. Whether for passenger car brake pads or heavy-duty applications such as aircraft and earth-moving equipment, iron powders offer a proven way to optimise brake pad materials for performance and cost efficiency.

Standardised sponge iron powders are widely used in semi-metallic and low-metallic brake pads. Their unique porous structure enhances the friction performance, improves weight ratio and reduces noise, since its irregular particle shape helps the resin to lock iron powder into the formulation matrix and absorb sound during braking. At the same time, the use of iron powder lowers the need for resin and copper content, reducing both production costs and environmental impact. This is a major benefit given today’s global stricter regulations on copper in brake pad applications.

Compared to other brake pad materials such as NAO (non-asbestos organic) or ceramic, semi-metallic formulations with iron powder offer competitive costs and improved thermal diffusivity. For sintered brake pads used in motorcycles, aircraft or trains, iron-based friction materials also provide a lower-cost alternative to copper-based ones, while maintaining excellent durability under extreme loads.

At Höganäs, we offer the world’s most comprehensive range of iron powders for friction material brake pad applications, engineered for consistency and quality. Our products help you design brake pad materials that minimise wear, reduce noise and ensure reliable performance in every application.