Starfire® Systems Takes Friction Materials to the Next Level

Starfire® has been working on the development of composite friction materials for about three years. The initial development, funded by the Air Force, was the testing of lighter weight composite aircraft brakes. In the program, Starfire's composite material system was compared with several other potential materials systems and had the best mechanical properties, best overall friction performance, and the lowest wear.

Since that initial development effort, Starfire® continues to work with the aircraft brake companies but there has been a stronger interest in motorcycle and automotive brakes. In automotive brakes, the lightweight material reduces the amount of energy required to accelerate the car, reducing fuel consumption, and increasing the acceleration rate. The improved fuel consumption is particularly noticeable in city driving, or stop-and-go driving, where there is more benefit from the "dynamic" weight savings. The estimated 4% improved fuel economy reported for the Tahoe demonstration vehicle was measured under an aggressive city driving cycle. The improvement in highway driving is considerably less.

The lightweight material also reduces the effort to overcome gyroscopic forces making the wheels easier to turn improving handling, especially at high speeds. This is really impressive in motorcycle handling where the affect makes it much easier and quicker for the rider to lean the bike into curves, especially at racing speeds. The material also does not fade; the friction coefficient actually increases as the brake gets hotter, opposite to that of conventional cast iron disk or drum brakes, improving performance and increasing safety. Another advantage is that the material is inherently quiet and smooth, dampening instead of amplifying noise, like a cast iron rotor will do. This is a huge advantage in today's automotive market where, 25% of new cars are returned during the warrantee period for brake noise, vibration, and harshness or NVH.

These nano-engineered materials are made by conventional composite manufacturing techniques using one or more of Starfire's unique ceramic forming polymers. At high temperature these polymers are converted to ceramics which are extremely temperature and wear resistant. The closest similar performing material is Carbon/Carbon which is currently used in Formula 1 racing and aircraft brakes, but it is extremely expensive, has a high wear rate only lasting one race, and is susceptible to low friction after absorbing moisture making it unsuitable for street use and recurring problems in aircraft.

Starfire® will soon commence limited production of our StarBlade® motorcycle rotor blades. Working in concert with partners this product will be available to the motorcycle aftermarket. StarBlade®, ceramic composite rotor blades, will fit to an aluminum carrier uniquely designed to properly mount the brake rotor assembly and will reduce the total weight 60-70% compared to the conventional steel or stainless steel rotors currently found on most racing and street bikes.

StarBlade®