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Purpose: The purpose of this paper is to deal with the tribological study on the brake pads developed using various purity-based graphitized graphite. Design/methodology/approach: This paper deals with developing copper-free brake pads by using graphite as a key lubricant produced using a graphitization process with purity percentages (85, 90 and 95%). The brake pads were developed using traditional manufacturing processes and evaluated for their physical, chemical, thermal and mechanical properties as per industrial standards. Fade and recovery characteristics were analyzed using a full-scale inertia brake dynamometer as per JASO-C-406. The scanning electron microscope was used to analyze the worn surfaces of the brake pads. Findings: The testing findings reveal that the brake pads with 95% graphitized graphite showed better shear strength with good adhesion levels and lesser density, hardness, acetone extract value, loss on ignition and higher porosity. Effectiveness studies of brake pads with graphite (95% graphitized) showed better results at higher pressure speed conditions than others because of better plateau formation and adequate lubrication. Originality/value: This paper discusses graphitized graphite of different purity influences brake pad's tribological performance by modifying tribo-films and reducing friction undulations. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to investigate the influence of commercially available iron–aluminum alloy compared to copper, iron and aluminum powders on the tribological performances of friction composites. The main objective is to replace copper from the friction composite formulations. Design/methodology/approach: In this study, friction composites were fabricated as of standard brake pads using commercially available iron–aluminum alloy and compared to copper powder, iron powder and aluminum powder-based without varying the other ingredients. The brake pads were developed as per the industrial procedure. The physical, mechanical and thermal properties of the developed brake pads were analyzed as per industrial standards. Tribological properties were analyzed using the chase test. Initial speed and deceleration tests in a real-time braking scenario were performed using a full-scale inertia brake dynamometer. Worn surface analysis was done using a scanning electron microscope. Findings: The results indicate that iron–aluminum alloy (mechanomade)-based friction composites possess good physical, chemical, thermal and mechanical properties with stable fade and recovery characteristics due to its composition and flake morphology. During initial speed and deceleration braking conditions, iron–aluminum alloy also showed good tribological behavior. Originality/value: This paper explains the influence of commercially available iron–aluminum alloy in friction composites in enhancing tribological performance by its composition and flake morphology, which could potentially replace copper in friction composites by solving subsequent problems. [ABSTRACT FROM AUTHOR]