金屬基摩擦材料因其在高溫時仍能維持一定的摩擦係數，而不產生高溫退化的現象，因而可以使用的範圍較為寬廣、較不會因環境的不同而造成摩擦特性的改變。然而，金屬基摩擦材料因為製程比半金屬基摩擦材料複雜，因而限制了金屬基摩擦材料的發展。本論文的一大重點即在討論銅基摩擦材料製程、成分對其性質的影響，期能藉由改變製程條件，而製出低成本、高性能的金屬基摩擦材料。
研究結果顯示，本研究所提出之大氣燒結銅基摩擦料不論在摩擦係數或磨耗量、及其熱穩定性方面，均比商用者具有較佳的性質，而且在連續多次的模擬煞車的測試上，本銅基摩擦材料也表現出極高的穩定性及再現性，這證明了大氣燒結的可行性。本研究所提出之製程，較一般高溫真空爐、保護氣氛控制之粉末冶金製程，可大幅地降低投資及生產成本，同時也比商用者具有更穩定的摩擦係數及較低摩擦厚度損失。
實驗的第二階段即著重於碳、鋁含量的變化以及製程參數對燒結銅基摩擦材料的性質影響。燒結後銅基摩擦材料的密度皆下降，這可能是因為燒結過程中產生氧化物及孔隙率的增加。使用較低的壓模壓力(394 MPa)及較慢的升溫速率(0.5 0C/min)，可以降低20 vol%碳＋10 vol%鋁試片燒結後的孔隙度，而且使得其密度由高壓(590 MPa)、快速(10 0C/min)製程中的3.93 g/cm3提高至4.26 g/cm3。在等速摩擦測試中，隨著試片碳含量的增加，摩擦係數與摩擦溫度都會上升，雖然，20 vol%碳＋10 vol%鋁的試片在利用高壓、快速的製程燒結後會得到高且穩定的摩擦係數(m= 0.5~0.6)，但是磨耗量卻過大(0.178 g)，而利用較低壓模壓力及較慢的燒結速度，可以使得相同的試片的磨耗量大幅下降(0.006 g)，同時也能維持相當的摩擦係數(m= 0.4~0.5)。摩擦測試的結果發現，不添加鋁及添加20 vol%的鋁都會對摩擦測試有負面的效果，因此，最佳的組合為添加10 vol%的鋁。EDS及磨面觀察分析結果顯示，在試片上形成一層轉移層，可以保護試片，而降低摩擦所造成的摩擦重量損失。50次模擬煞車結果顯示，20 vol%碳＋10 vol%鋁的試片擁有高的摩擦係數(m= 0.55~0.65)及低磨耗量(0.023 g)，因此，適合作為一煞車摩擦材料。
本研究的結果顯示，大氣下燒結的銅基試片能具有良好的摩擦特性。利用較低壓模壓力及較慢的升溫速率燒結20 vol%的碳＋10 vol%鋁的試片，擁有高摩擦係數低磨耗量，是一良好的金屬基摩擦材料。

Metallic friction materials are used for their high thermal resistance. They are usually used in sever environments or in heavy-duty conditions. Although the friction behaviors of metallic friction materials are better than semi-metallic materials, the complex manufacture process constrains the usage of metallic friction materials. The first part of this study was to sinter friction material in air.
It may be understood from the data of the tests that friction materials of the present works have very high thermal and tribological stability. Further, the air-sintered process reduces largely the investment and productive cost compared to the conventional power metallurgy methods using a high temperature vacuum/inert furnace under a protective atmosphere, and at the same time the products of the present work has a higher friction coefficient and better wear characteristics than the commercial products.
In the second part, the focus of the study has been placed on the effect of graphite, aluminum content and process parameters on tribological behavior of a Cu-based friction material sliding against FC30 cast iron. Experimental results indicated that the densities of the Cu-based specimens sintered in air were decreased, and the oxygen contents were increased. Althlough 20 vol% C +10 vol% Al specimen (by compacted at 590 MPa and treated with 10 0C/min heating rate) possessed highest friction coefficient (m= 0.5~0.6), its weight loss was too large (0.178 g). After choosing lower compaction pressure (394 MPa) and lower heating rate (0.5 0C/min), 20 vol% C +10 vol% Al specimen had high enough friction coefficient (m= 0.4~0.5) and low weight loss (0.006 g). The results of wear tests indicated that samples with the 20 vol% or 0 vol% Al contents were not desirable. The observation of the worn surfaces showed that the transfer film can protect the specimens. The simulation data indicated that 20 vol% C +10 vol% Al specimen (by compacted at 394 MPa and treated with 0.5 0C/min heating rate) had a high friction coefficient (m= 0.55~0.65) and a low weight loss (0.023 g).
It was concluded that the addition of 20 vol% graphite and 10 vol% aluminum by using lower compaction pressure and lower heating rate was beneficial to improve the properties of air-sintered Cu-based friction materials.

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