Abstract In this study, asbestos-free automotive brake pads produced from palm kernel fibers
with epoxy-resin binder was evaluated. Resins varied in formulations and properties such as friction
coefficient, wear rate, hardness test, porosity, noise level, temperature, specific gravity, stopping
time, moisture effects, surface roughness, oil and water absorptions rates, and microstructure examination
were investigated. Other basic engineering properties of mechanical overload, thermal
deformation fading behaviour shear strength, cracking resistance, over-heat recovery, and effect
on rotor disc, caliper pressure, pad grip effect and pad dusting effect were also investigated. The
results obtained indicated that the wear rate, coefficient of friction, noise level, temperature, and
stopping time of the produced brake pads increased as the speed increases. The results also show
that porosity, hardness, moisture content, specific gravity, surface roughness, and oil and water
absorption rates remained constant with increase in speed. The result of microstructure examination
revealed that worm surfaces were characterized by abrasion wear where the asperities were
ploughed thereby exposing the white region of palm kernel fibers, thus increasing the smoothness
of the friction materials. Sample S6 with composition of 40% epoxy-resin, 10% palm wastes, 6%
Al2O3, 29% graphite, and 15% calcium carbonate gave better properties. The result indicated that
palm kernel fibers can be effectively used as a replacement for asbestos in brake pad production