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Besides elimination of copper, the eco-friendly brake materials are developed using geopolymer matrix and natural fibers to replace phenolic resin and synthetic fibers, respectively. The objectives are to diminish i) the amount of volatile organic compounds (VOCs) being released from the brake materials when subjected to temperatures higher than 300 °C; and ii) release the potentially hazardous wear debris particles to the environment. Brake materials were fabricated in university and tested using SAE J2430 test procedure and full scale automotive brake dynamometer (Dyno). Dyno test results indicate that the average friction level of the eco-friendly Cu-free materials (µ ∼ 0.30 to 0.33) was only slightly lower when compared to the baseline material containing Cu (µ ∼ 0.35). All tested materials have passed the Brake Effectiveness Evaluation Procedure (BEEP).

The major goal of this research study was to address the possible replacement of copper and selected solid lubricants by environmentally friendly hexagonal boron nitride (h-BN). Model friction samples were manufactured and subjected to friction assessment and screening tests (FAST) and full scale automotive brake dynamometer (Dyno) tests. The SAE recommended J2430 procedure provided the necessary data for the Brake Effectiveness Evaluation Procedure (BEEP) by Brake Manufacturers' Council. The obtained results indicate that the overall coefficient of friction, as detected in FAST, increased with respect to baseline with a 1:1 substitution of h-BN for either Cu or metal sulfides (Sb₂ S₃ and MoS₂). The thickness losses in FAST tests were similar or lower when h-BN was being used to replace copper and metal sulfides, except for the HCR type of h-BN.