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In recent years, asbestos and copper free brake pads have attracted researchers due to its adverse environmental risks which requires manufacturers to seek a suitable replacement. It is essential to identify new combination of synthetic and natural fibers for the potential automotive brake pads. Experiments were planned to produce various frictional composites by using additives like carbon fiber and basalt fiber with standard additional ingredients like binders, fillers, abrasives and lubricants through hot pressing technique. Here binder act as epoxy resin is mixed with these frictional composites and graphite act as lubricant, vermiculite act as filler and alumina act as abrasives. The prepared form of polymer composite brake pad materials was tested as per ASTM and industrial standard practices like hardness, wear and friction followed by worn surface roughness were measured.

The critical components in earlier were manufactured by mild steel but due to low corrosion resistance, stainless steel and aluminium alloy are being utilised. However a component of aluminium alloy has to be enriched by anodizing for long durability and better corrosion resistance. But peel off, pit formation, low adhesion and white rust formation are still the downfalls faced by the industries in the coated components over cyclic duration. High-Velocity Oxy-Fuel (HVOF) thermal spraying is an adaptable method that can produce high-density coating with less than 1% porosity, high resistant to chemical environment providing better adhesion and increase the life of mating components. Though stainless steel and anodized aluminium alloy offers far superior life span and corrosion resistance but still more expensive than mild steel.