Fabrication of Asbestos-free Brake Pads Utilizing Sustainable Coconut Shell Material: A Mechanical Investigation
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Abstract
This study introduces an innovative coconut shell material for the fabrication of asbestos-free brake pads. The brake pads were manufactured using coconut shell powder in particle sizes of 200 µm, 300 µm, 400 µm, and 500 µm. The produced brake pads are evaluated for their morphological, mechanical, and physical qualities. Scanning electron microscopy pictures demonstrated that coconut shell powder was uniformly dispersed throughout the brake pad, signifying robust interfacial adhesion with the resin. The generated samples underwent density measurement, hardness testing, compressive strength analysis, and wear evaluation using a pin-on-disc tribometer. Thermal stability and fade-recovery properties were assessed, while Scanning Electron Microscopy (SEM) provided insights into interfacial adhesion and wear morphology. The results demonstrated that optimal coconut shell content enhanced hardness, compressive strength, and wear resistance, while maintaining a stable coefficient of friction under diverse operating conditions. Strong interfacial adhesion between particles and the resin matrix improved endurance and minimized material degradation during braking. This study demonstrates that coconut shell powder acts as a sustainable and cost-effective reinforcement for non-asbestos brake pads, offering beneficial mechanical and tribological properties while promoting waste reutilization and eco-friendly manufacturing.