Braking performance of friction materials: a review of manufacturing process impact and future trends

Abstract

The brake friction materials are composite materials with multi-ingredient systems which induce a complex formulation. This complexity is also the result of the manufacturing parameters effects, such as mixture sequence and duration, moulding pressure, time, temperature and heat treatment time. Therefore, heterogeneity is induced as well in the characteristics (microstructure, density, etc.) as in the behaviour (mechanical, tribological, dynamic, etc.). Despite the study of the effect of manufacturing parameters on the friction material behaviour, the synergistic effect between the heterogeneity and the braking performance is still not well reported. This paper strives to eliminate the cloud of uncertainty of the role of manufacturing parameters on the friction material performances by providing most used process of elaboration, and most required properties for contemporary brake system. Innovation in brake discs and pad manufacturing by optimized algorithms, prediction approaches, and 3D printing process is presented as innovative methods to improve braking materials performance.

Recent progress in the research on natural composite brake pads: a comprehensive review

“…The advantage of additive manufacturing can be used in the brake pad manufacturing process. Also, the challenges exist in the additive manufacturing process of brake pads needs great attention [134]. The advancements in the electric vehicles production are demanding a novel friction material for brakes [135].…”