Development and performance evaluation of eco-friendly, asbestos-free brake pads using doum shell biomaterial

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Mba, Chidiadi Bethel and Alozie, Uchenna Henry and Sunday, Macdonald Chinyere and Iwediba, Isaac Ifeanyi and Onyeukwu, Kelechi Jude and Okafor, Onyekachi Monday and Iwediba, Emmanuel Onyebuchi and Effiong, Daniel Edem and Onwuka, Uzochukwu Frankline (2026) Development and performance evaluation of eco-friendly, asbestos-free brake pads using doum shell biomaterial. Bulletin of the National Research Centre, 50 (1). 50. ISSN 2522-8307 (https://doi.org/10.1186/s42269-026-01435-6)

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Abstract

The accelerated growth of population and the rise in the number of vehicle owners are expected to create a sharp demand in the global market for brake pads, which will exert an acute demand to substitute asbestos-containing materials. Asbestos, which was previously employed in friction composites, is dangerous and does not withstand hot climates; hence, substitutes with safer ones are required. This paper explores the utilization of doum palm shell (DPS) as an agro-waste that contains silica as a reinforcement in asbestos-free brake pads manufactured using phenolic (PR) and epoxy (EP) binders. DPS is biodegradable, economical, and locally available, and it helps in valorizing waste and recovering resources that are sustainable. Graphite, glass fibre, aluminium oxide, and alkali-treated DPS were used to create brake pads. FTIR analysis showed better bonding, and TGA showed better thermal stability in EP and more char yield with better flame resistance in PR. Compressive strengths of EP samples of 47–77 MPa and impact energies of 4.27–7.09 J/m² were obtained in mechanical tests, compared to 70.12–80.20 MPa and 8.75 J/m² in PR samples. Hardness peaked at 95.6 Hv in S1PR. The tribological analysis showed that PR composites had lower wear levels and increased friction coefficients, while EP had high thermal resistance and lower water absorption (0.098%). The best performance was recorded in S2PR with 20 g DPS and 15 g glass fibre, which had a balance between strength and friction. Phenolic binders outperformed epoxy in tribological criteria, while epoxy had greater heat stability. The results reveal that DPS is a potential reinforcement in the manufacturing process of sustainable brake pads. Future research ought to address fade and recovery behaviour, thermo-mechanical coupling, and long-term durability. Graphical Abstract:

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