Case Studies
INNOVATION:Rapid Response, New Material!
APPLICATION: TRUCK CLUTCHES
THE CHALLENGE: Increased power levels at clutch engagement created a costly repair problem.
THE WELLMAN SOLUTION: Develop a new material, test it and get it into production – FAST!
Using advanced optimization techniques, the Wellman engineering and research & development teams perfected an innovative product combining materials and process breakthroughs.
THE RESULT:Wellman delivers friction solution!
- Flywheel wear reduced by 75%
- Superior coefficient of friction
- Friction life extended by 30%
- Driver fatigue reduced
And it was done ahead of schedule and within target costs.
INNOVATION:Cool Runners!
APPLICATION: “HOT ROD” MINING TRUCK BRAKES
THE CHALLENGE:A mine owner complained of failing wet brake components on his giant ore hauling trucks. Operators ran fully loaded trucks at 18 mph downhill, while the operating specification called for a maximum of 8 mph. Merely telling the drivers to “slow down” would be impractical and ineffective.
THE WELLMAN SOLUTION:Develop a new paper formulation that withstands much higher operating temperatures and shear forces, and does not fade.
(Re-engineering brake design was not an option.)
THE RESULT:Wellman develops revolutionary carbon paper friction material that sets a new standard for wet brake friction performance. Key improvements included increased coefficient of friction, stable torque output, elevated heat capacity and dramatically extended friction & steel disc life. The mine owner was extremely pleased and realized numerous benefits from the upgrade.
- Reduced downtime
- Higher productivity
- Motivated drivers
- Improved safety
- Increased profitability
INNOVATION:Aircraft-Like Performance!
APPLICATION:MILITARY VEHICLE BRAKES
THE CHALLENGE:The manufacturer of a four-wheel drive military vehicle wanted to broaden the vehicle’s military applications by adding communications equipment and more armor. These modification doubled vehicle weight causing the brakes to virtually self destruct. Recorded brake temperature exceeded 1400°F. Though Wellman was not the original brake supplier, the manufacturer asked us to solve the problem.
THE WELLMAN SOLUTION:Wellman developed a new, heavy-duty material similar to an aircraft brake product and incorporated some innovative brake pad design improvements.
THE RESULT:MISSION ACCOMPLISHED! Wellman's new brake pad product performed flawlessly and immediately replaced the incumbent product around the globe.
