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In this paper, an investigation of the load-dependent wear behavior of copper-free semi-metallic brake material is presented. The experiments were conducted in ambient thermal settings with varying sliding velocities (3.141 m/s, 2.09 m/s, and 1.047 m/s), normal load (60 N, 50 N, and 40 N), and sliding distance (4500 m, 3000 m, and 1500 m). Taguchi’s method was used in designing experiments to examine the output through an L9 orthogonal array. ANOVA was used to identify the consequence of interactions among different constraints. It also established the significant contribution of each process factor. The objective was set as the ‘smaller is better’ criterion to find minimum wear conditions. The impact of the normal load on the wear process was found to be maximum (71.02%), followed by sliding velocity (27.84%) and sliding distance (1.14%). The optimum condition for the minimum wear rate was found at 40 N normal load, 1500 m sliding distance, and 3.14 m/s sliding velocity. The results were confirmed with validatory friction experiment runs. The resulting error was within 10% error, which verified the experiment methods. The SEM investigation of worn surfaces of pin and disc confirmed abrasive wear and adhesive wear at 60 N and 40 N, respectively.

Semi-metallic brake pads are more durable, fade-resistant, and long-lasting; thus, their tribological qualities are further studied. Taguchi's experimental technique is crucial for determining the impact of various braking limitations on semi-metallic brake pad performance. Taguchi's approach was utilized to create an experimental design using an L9 orthogonal array to examine the output. The effect of multiple parameter interactions and the relative contributions of each studied control is determined using ANOVA. At room temperature and humidity, tests were done under dry sliding circumstances with changing sliding velocity (1.047 m/s, 2.094 m/s, and 3.141 m/s), applied weight (40 N, 50 N, and 60 N), and sliding distance (1500 m, 3000 m, and 4500 m). ANOVA was used to determine the impact of the test constraints on the wear rate throughout the run. A multiple linear regression formula was established. The dry sliding wear resistance was investigated utilizing the 'smaller is better' criteria. In this study, the normal load has the maximum impact (71.02%), followed by sliding velocity (28.13%) and sliding distance (1.14%). The optimal functioning settings found after analysis, include a 40 N applied weight, a 1500 rpm sliding velocity, and a 1500 m sliding distance. This was also confirmed by SEM analysis. Lastly, validation tests were performed to double-check the experiment's results. The difference between calculated and actual values was discovered to be less than 10% which is in agreement with the methodology followed.