Tribological performance of chitosan-filled aloe vera fiber–reinforced polyester composites for automotive brake pad applications

Traditional brake pads often contain metal-based components, leading to environmental pollution, high wear rates, and noise issues. This study explores an aloe vera fiber–reinforced polyester composite with chitosan for automotive brake pad applications. Developing sustainable, lightweight, and wear-resistant alternatives is essential. The composite exhibits low void content (3.13 %) and water absorption (2.41 %), ensuring moisture resistance. Its density (1.51 g·cm −3 ) indicates a well-structured material with minimal defects. Mechanical properties include hardness (86.2), impact energy (4.2 J), tensile strength (94.6 MPa), flexural strength (154.68 MPa), and shear strength (146.94 MPa), making it suitable for high-friction applications. Tribological analysis shows wear decreases with sliding distance due to a protective layer formation. Friction is mainly influenced by applied load, followed by velocity and distance. Taguchi optimization identifies ideal conditions for minimal wear (20 N , 1,500 m, 2 m·s −1 ) and friction (40 N , 500 m, 2 m·s −1 ). ANOVA confirms sliding distance as the main wear factor, while load affects friction most. SEM analysis shows debris, delamination, and crack. These findings highlight the composite’s potential as a sustainable, wear-resistant alternative for automotive brake pads, offering enhanced durability and reduced environmental impact.