Optimizing Brake Pad Performance of a Composite Materials Prepared with Smilax Zelanica/Glass Fiber and Nano Silica Across Diverse Sieve Variations

This groundbreaking study aimed to enhance the efficiency and durability of brake pads by developing a novel composite material composition. The research focused on integrating alkali-treated smilax zelanica/glass fiber reinforcements with nano silica to improve the mechanical, structural, and performance properties of brake pads. Comprehensive tests were conducted to evaluate friction, wear, and shear characteristics under various conditions. The results demonstrated significant enhancements in these properties, attributed to the synergistic effects of the composite materials. Scanning electron microscopy (SEM) analysis provided detailed insights into the microstructure and failure mechanisms, confirming strong bonding between the reinforcing fibers, Nano silica particles, and the matrix material. The study’s methodology involved fabricating brake pad samples with different proportions of sieves measuring 180 μm and 250 μm, varying the ratio of matrix to reinforcements. Among these, the combination of 70% matrix and 30% reinforcements exhibited superior mechanical properties. Samples underwent chemical treatment and sieve processes before formulation, blending filler, fiber, binder, and frictional additives. Hydraulic pressing and curing processes were employed to produce the final brake pads. Physical and mechanical testing included density, porosity, hardness, and impact strength assessments. Results showed that samples with smaller particle sizes exhibited higher density, lower porosity, greater hardness, and superior impact strength, indicating improved mechanical properties. Performance testing using a brake pad test rig demonstrated the composite material’s promising efficiency and sustainability. The observed improvements signify a significant advancement in brake pad technology, offering durable, efficient, and environmentally friendly solutions for the automotive industry. SEM analysis further confirmed variations in microstructure among samples, with denser structures exhibiting better mechanical properties. Comparison with asbestos-based brake pads showed superior performance of the composite materials in terms of wear rate, tensile strength, hardness, compressive strength, friction coefficient, thermal conductivity, specific gravity, and resistance to swelling in oil and water. The study highlights the efficacy of alkali-treated smilax zelanica/glass fiber and nano silica composite materials in improving brake pad performance compared to conve