Tribological and mechanical performance of graphite-based brake pads modified with SiC, MgO, and aramid fiber reinforcements

This study presents an experimental investigation of graphite-based automotive brake pad composites reinforced with ceramic particles and fibers to improve friction stability, wear resistance, and thermal performance. Three brake pad formulations were evaluated: one commercial reference sample (S1) and two laboratory-developed composites (S2 and S3). The specimens were fabricated by hot pressing followed by post-curing. Microstructural characterization using SEM–EDX and XRD confirmed improved filler dispersion and stronger interfacial bonding in the developed composites, particularly in S2 containing silicon carbide (SiC) and aramid fibers. Mechanical testing showed increased hardness for the developed samples compared with the commercial pad. Tribological tests demonstrated that S2 achieved the best overall balance of high friction performance and low wear rate, while S3 exhibited stable friction behavior under moderate loads. Thermogravimetric analysis indicated enhanced thermal stability for the reinforced formulations compared with the reference sample. Worn surface analysis revealed a transition from severe abrasive wear in S1 to protective tribo-film formation in S2 and S3. Overall, S2 showed the most promising combination of hardness, friction stability, wear resistance, and thermal durability, making it a suitable candidate for advanced braking applications.