Breakthrough Technology Harnesses Lightning in a Box to Revolutionize Steel

SAN DIEGO, Jan. 10, 2012 /PRNewswire/ -- PureForge™, a corporation that develops innovative products using its revolutionary Atomic-Forging™ technology, announces university laboratory testing validating that their first product to market – vehicle brakes – outlast, outperform, and create less toxic brake dust than any other current automotive brake offering.  The Center for Advanced Friction Studies at Southern Illinois University Carbondale tested and compared the PureForge Ford Crown Victoria brake rotor with the standard OEM rotor and noted the clear distinctions.  PureForge will market these brakes to law enforcement fleets first.

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Independent Testing

The results of the independent university laboratory testing confirms PureForge's bold claims that their rotors will last the lifetime of the vehicle, outperform, and produce less brake dust than all other current braking systems.  Dr. Peter Filip, Director of the Center for Advanced Friction Studies and a renowned brake expert, noted, "In my 15-year career working with friction materials, I have had the vision that a braking system could be developed that effectively stops the vehicle under a variety of conditions and that can reduce toxic environmental emissions to near-zero.  I am confident the PureForge technology provides just such a braking system."

Dr. Filip and his team at the Center for Advanced Friction Studies conduct research in areas of fundamental interest to the friction industry.  The center is recognized as the premier research facility in the U.S. and worldwide for the study of materials and phenomena associated with braking systems. In fall 2011, the researchers tested PureForge and OEM Ford Crown Victoria (2007 model) rotors on a brake dynamometer at the center's facility using SAE testing guidelines J2430-FMVSS 135. During the dynamometer tests, the parameters such as braking speed, release speed, stop time, stop distance, deceleration, torque, effectiveness, pressure, and pad temperature were adjusted and recorded.

No Rotor Wear for Reduced Costs

The testing results proved that PureForge rotors differ significantly from the OEM rotors in terms of wear, performance, and brake dust.  To test wear, the rotors were individually weighed and measured at four different positions. While the OEM brake rotors showed visible and measurable signs of wear, PureForge rotors showed absolutely no detectable wear.  Wear is a common problem among braking systems as the average rotor must be replaced every 15,000-30,000 miles.

Better Performance for Increased Safety

Regarding performance, the testing results prove that PureForge rotors, paired with standard brake pads, improve braking performance by maintaining constant friction levels across broad conditions and operating temperatures. Braking performance translates directly to shorter stopping distances and as a direct result, safer drivers. While traditional rotors reach a peak temperature at which time the friction levels decrease, PureForge's rotors maintain a constant friction level regardless of temperature. With constant friction levels, the rotors perform the same in all conditions—slow and fast speeds, hot or cold. According to Dr. Filip, "PureForge rotors enable braking system performance that has previously been unachievable."  PureForge rotors also demonstrated no fade and no speed sensitivity in the performance tests, a significant motor vehicle safety breakthrough.

Less Brake Dust for Smaller Environmental Impact

As part of the testing protocol, researchers collected and analyzed brake dust debris through a filtration system attached near the rotor.  PureForge rotors produced significantly lower brake dust emissions than the OEM rotors. The lower brake dust emissions are a true breakthrough in green technology. In addition to reducing brake dust emissions, the longer rotor life means significantly fewer rotors will be produced and disposed.

Atomic-Forging Technology

PureForge brakes differ from OEM brakes in the materials and process used to manufacture the rotors. Through a process known as Atomic-Forging, PureForge rotors are treated with a lightning-like effect in a specially-designed chamber to change the molecular nature of steel to make it stronger. This patented and patent-pending technology is the secret behind the durability and performance of the rotors.

Business Opportunities for PureForge

With their Atomic-Forging technology, PureForge believes that they have the "perfect storm" of opportunity to create more U.S. jobs, help the environment, and offer a safer, cost-saving braking solution.  PureForge currently markets their technology and products to law enforcement vehicle fleets, with plans to expand into government and commercial fleets within the next 5 years. PureForge's innovative maintenance and service agreement enables the company to outfit fleet vehicles with PureForge brakes for no up-front cost, and charge a monthly service fee that saves the fleet money.  This instant savings allows police departments to reduce brake maintenance costs during a time when budgets are strained.

Beyond brakes, PureForge sees many high-friction applications for its Atomic-Forging technology, ranging from medical implants to aerospace applications. The company is limited only by the capital needed to scale and grow to fill the need for their technology. The private-equity financed PureForge sees opportunity for financial help from an unlikely source, as company executives are in negotiations with South Dakota over a $30 million package of grants and low-interest loans to move manufacturing to the state and add 94 jobs within 5 years.

The independent laboratory testing by the Center of Advanced Friction Studies at Southern Illinois University Carbondale proves the effectiveness of the PureForge rotor and their revolutionary technology. The successful testing marks the first step in development of the PureForge Crown Victoria police rotors which are scheduled for market debut near the end of 2012. As PureForge rotors outlast, outperform, and produce less harmful brake dust than all other braking systems, the automotive industry is taking notice of this California start-up and their Atomic-Forging technology.

About PureForge

PureForge is a San Diego, California-based corporation that manufacturers innovative products through their revolutionary Atomic-Forging Technology. Founded in early 2006, PureForge's revolutionary clean brake technologies have consistently increased brake performance and safety while decreasing brake wear and environmental pollutants.  For more information on PureForge, please visit http://www.pureforge.com. 

About the Center for Advanced Friction Studies

A University-based research center located at Southern Illinois University Carbondale that focuses on areas of fundamental interest to the friction industries. The Center for Advanced Friction Studies focuses on education of undergraduate and graduate students in the science of friction materials, as well as conducting proprietary research for the friction industry.  Dr. Peter Filip is the Director of the Center. 

SOURCE PureForge