Mechanical Characterization of Green Composite Brake Pads Reinforced with Coconut Shell Waste

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 1636 1648
    By

    Swapnil Lokhande,

  • Mohammed Ali,

  1. Research Scholar, Department of Mechanical Engineering, Oriental University, Indore, Madhya Pradesh, India
  2. Professor, Department of Mechanical Engineering, Oriental University, Indore, Madhya Pradesh, India

Abstract

In the present work, coconut shell powder proposed as a replacement material for the eco-friendly brake linings. The composites for brake pad were developed with other sizes of the coconut shell particles, namely (200 µm, 300 µm, 400 µm and 500 µm) The developed samples were evaluated for morphological, mechanical, physical and worability properties. The SEM micrograph proved that the coconut shell particulates are well dispersed in the composite everywhere and also shows good interfacial adhesion between reinforcement and resin. The attempted brake pads were densified measured, hardness tested, compressive strength extruded via a pin-on-disc tribometer for wear analysis. Its thermal stability and fade and recovery performance were also studied. The wear mechanisms as well as the performance of interfacial adhesion were also characterized by SEM after examination. The optimum coconut shell content identified that enhanced surface hardness, compressive strength, wear resistance and retained a low stable coefficient of friction irrespective of the service parameters. The superior performance was ascribed to good interfacial adhesion of the coconut shell particles with the resin matrix, leading to higher durability and lower wear loss during braking. In general, the results obtained confirm coconut shell powder as a low-cost and eco-friendly reinforcement to be used in NA braked applications, contributing for greener manufacturing practices by allowing the environmentally friendly re-use of agro-waste. In comparison to bigger particle sizes, the brake pad augmented with 300 µm coconut shell particles showed better hardness and a lower wear rate while retaining stable friction behavior. The study shows that turning coconut shell agricultural waste into a high-performing, ecologically friendly brake pad material is feasible.

Keywords: Brake pad, Asbestos, Automobile, Natural materials, Composite materials

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Swapnil Lokhande, Mohammed Ali. Mechanical Characterization of Green Composite Brake Pads Reinforced with Coconut Shell Waste. Journal of Polymer & Composites. 2026; 14(01):1636-1648.
How to cite this URL:
Swapnil Lokhande, Mohammed Ali. Mechanical Characterization of Green Composite Brake Pads Reinforced with Coconut Shell Waste. Journal of Polymer & Composites. 2026; 14(01):1636-1648. Available from: https://journals.stmjournals.com/jopc/article=2026/view=236583


Browse Figures

References

  1. Afolabi M, Abubakre OK, Lawal SA, Raji A. Experimental Investigation of Palm Kernel Shell and Cow Bone Reinforced Polymer Composites for Brake Pad Production. International Journal of Chemistry and Materials Research [Internet]. 2015 Jan 1 [cited 2025 May];3(2):27. Available from: https://doi.org/10.18488/journal.64/2015.3.2/64.2.27.40
  2. Ibhadode AOA, Dagwa IM. Development of asbestos-free friction lining material from palm kernel shell. Journal of the Brazilian Society of Mechanical Sciences and Engineering [Internet]. 2008 Jun 1 [cited 2025 May];30(2). Available from: https://doi.org/10.1590/s1678-58782008000200010
  3. Krishnan GS, Loganathan GB, Pradhan R, Kumar S. Study on tribological properties of palm kernel fiber for brake pad applications. Materials Research Express [Internet]. 2019 Nov 25 [cited 2025 May];7(1):15102. Available from: https://doi.org/10.1088/2053-1591/ab5af5
  4. Pinca-Bretotean C, Crăciun AL, Preda C, Sharma AK. Physico-mechanical and tribological characteristics of composites used for brake pads. Journal of Physics Conference Series [Internet]. 2021 Feb 1 [cited 2025 May];1781(1):12032.
  5. Available from: https://doi.org/10.1088/1742-6596/1781/1/012032
  6. Pujari S, Srikiran S. Experimental investigations on wear properties of Palm kernel reinforced composites for brake pad applications. Defence Technology [Internet]. 2018 Nov 27 [cited 2025 May];15(3):295. Available from: https://doi.org/10.1016/j.dt.2018.11.006
  7. Stojаnović B, Glišović J. Application of Ceramic Matrix Composite in Automotive Industry. In: Elsevier eBooks [Internet]. Elsevier BV; 2020 [cited 2025 May]. p. 275. Available from: https://doi.org/10.1016/b978-0-12-819724- 0.00018-5
  8. Baba ZU, Shafi WK, Haq MIU, Raina A. Towards sustainable automobiles- advancements and challenges. Progress in Industrial Ecology An International Journal [Internet]. 2019 Jan 1 [cited 2025 Jun];13(4):315. Available from: https://doi.org/10.1504/pie.2019.102840
  9. Abutu J, Lawal SA, Ndaliman MB, Lafia-Araga RA, Adedipe O, Choudhury IA. Production and characterization of brake pad developed from coconut shell reinforcement material using central composite design. SN Applied Sciences [Internet]. 2018 Dec 5 [cited 2025 May];1(1). Available from: https://doi.org/10.1007/s42452-018-0084-x
  10. Shrigandhi GD, Kothavale BS. Biodegradable composites for filament winding process. Materials Today Proceedings [Internet]. 2021 Jan 1 [cited 2025 Feb];42:2762. Available from: https://doi.org/10.1016/j.matpr.2020.12.718
  11. Jose AS, Athijayamani A, Jani SP. A review on the mechanical properties of bio waste particulate reinforced polymer composites. Materials Today Proceedings [Internet]. Elsevier BV; 2020 Aug 29 [cited 2025 Jun];37:1757.
  12. Available from: https://doi.org/10.1016/j.matpr.2020.07.360
  13. Krenkel W, Heidenreich B, Renz R. C/C-SiC Composites for Advanced Friction Systems. Advanced Engineering Materials [Internet]. 2002 Jul 15 [cited 2025 May];4(7):427. Available from: https://doi.org/10.1002/1527- 2648(20020717)4:73.0.co;2-c
  14. Yu S, Zhang Z, Wang Q, Ren M, Jia H. Study on wear resistance of local aluminum alloy reinforced by carbon fiber transfer membrane region. Journal of Materials Research and Technology [Internet]. 2023 Mar 1 [cited 2025 May];23:5772. Available from: https://doi.org/10.1016/j.jmrt.2023.02.121
  15. Firoozi AA, Firoozi AA, Oyejobi DO, Avudaiappan S, Flores ES. Emerging Trends in Sustainable Building Materials: Technological Innovations, Enhanced Performance, and Future Directions. Results in Engineering [Internet]. 2024 Nov24 [cited 2025 Jun];24:103521. Available from: https://doi.org/10.1016/j.rineng.2024.103521
  16. Gaurav G, Gohal H, Kumar VM, Jena H. Study of natural fibre composite material and its hybridization techniques. Materials Today Proceedings [Internet]. 2020 Jan 1 [cited 2025 Feb];26:1368. Available from: https://doi.org/10.1016/j.matpr.2020.02.277
  17. Jesthi DK, Nayak A, Mohanty SS, Rout AK, Nayak RK. Evaluation of mechanical properties of hybrid composite laminates reinforced with glass/carbon woven fabrics. IOP Conference Series Materials Science and Engineering [Internet]. 2018 Jun 1 [cited 2025 Jan];377:12157. Available from: https://doi.org/10.1088/1757-899x/377/1/012157
  18. Gadow R, Speicher M. Manufacturing of Ceramic Matrix Composites for Automotive Applications [Internet]. Ceramic transactions /Ceramic transactions. Wiley; 2006 [cited 2025 Jan]. p. 25. Available from: https://doi.org/10.1002/9781118380925.ch3
  19. Kumar AAJ, Ramaseshan NPA, Lakshmanan T. Tribological Analysis on Basalt/Aramid Hybrid Fiber Reinforced Polyimide Composites: An Alternate Brake Pad Material. Tribology in Industry [Internet]. 2021 Jun 15 [cited 2025 Feb];43(2):334. Available from: https://doi.org/10.24874/ti.912.06.20.12
  20. Shue B, Moreira A, Flowers GT. Review of Recent Developments in Composite Material for Aerospace Applications. 2009 Jan 1 [cited 2025 Jan];811. Available from: https://doi.org/10.1115/detc2009-87847
  21. Boria S. Lightweight design and crash analysis of composites. In: Elsevier eBooks [Internet]. Elsevier BV; 2016 [cited 2025 May]. p. 329. Available from: https://doi.org/10.1016/b978-1-78242-325-6.00013-x
  22. Kickelbick G. Introduction to Hybrid Materials [Internet]. Hybrid Materials. De Gruyter Open; 2006 [cited 2025 Jun]. p. 1. Available from: https://doi.org/10.1002/9783527610495.ch1
  23. Jawaid M, Khalil HPSA. Cellulosic/synthetic fibre reinforced polymer hybrid composites: A review. Carbohydrate Polymers [Internet]. Elsevier BV; 2011 Apr 30 [cited 2025 Feb];86(1):1. Available from: https://doi.org/10.1016/j.carbpol.2011.04.043
  24. Elbazze A, Radi B. Comparative study between plastic composites and steel in structural parts of automobile. Contemporary Engineering Sciences [Internet]. 2019 Jan 1 [cited 2025 Feb];12(4):267. Available from: https://doi.org/10.12988/ces.2019.91134
  25. Hackert-Oschätzchen M, Lehnert N, Martin A, Schubert A. Jet Electrochemical Machining of Particle Reinforced Aluminum Matrix Composites with Different Neutral Electrolytes. In: IOP Conference Series Materials Science and Engineering [Internet]. IOP Publishing; 2016 [cited 2025 May]. p. 12036.
  26. Available from: https://doi.org/10.1088/1757-899x/118/1/012036
  27. Basha UM, Krishnudu DM, Hussain P, Reddy KM, Karthikeyan N, Kumar MA. Synthesis and Characterization of Natural Fibers Reinforced Fiber Epoxy Composites. International Letters of Chemistry Physics and Astronomy [Internet]. 2015 May 1 [cited 2025 Jun];51:47. Available from: https://doi.org/10.18052/scipress.com/ilcpa.51.47
  28. Kumar AP. Recent Advances of Hybrid Fiber Composites for Various Applications [Internet]. 2020 [cited 2025 Jan]. p. 381. Available from: https://doi.org/10.1002/9783527824571.ch18
  29. Bai X, Zhang X. Artificial Intelligence-Powered Materials Science. Nano- Micro Letters [Internet]. Springer Science+Business Media; 2025 Feb 6 [cited 2025 Jun];17(1). Available from: https://doi.org/10.1007/s40820-024-01634-8
  30. Yu X. Machine learning application in the life time of materials. arXiv (Cornell University) [Internet]. 2017 Jan 1 [cited 2025 Feb]; Available from: https://arxiv.org/abs/1707.04826
Special Issue Subscription Original Research
Volume 14
Special Issue 01
Received 17/01/2026
Accepted 04/02/2026
Published 14/02/2026
Publication Time 28 Days
105

Login


My IP

PlumX Metrics