Performance Evaluation of Lignocellulosic Fiber‐Reinforced Brake Pads Using Hybrid Optimization Techniques

ABSTRACT This study investigates the use of lignocellulosic fibers (LF) as sustainable reinforcements in brake pad formulations, integrating experimental characterization with multi‐criteria decision‐making. Three formulations were produced: a Cu‐free (Lf10), a hybrid (Lf5), and a Cu‐containing reference brake pad (Lf0). Comprehensive evaluation of physical, mechanical, thermal, and tribological properties, including density, hardness, porosity, thermal conductivity, friction coefficients, and wear, was conducted. A standardized Chase‐type friction wear testing machine (SAE J661) assessed fade–recovery behavior, and SEM/EDX analyses characterized microstructural and elemental features. Increasing LF content reduced density and thermal conductivity but enhanced low‐temperature friction and recovery. Lf0 exhibited the lowest wear (0.59 g), lowest friction (normal μ = 0.39, hot μ = 0.39) and highest hardness (115.8 HRR), whereas Lf10 displayed high initial friction but reduced thermal stability and the highest wear (0.75 g). The hybrid Lf5 formulation offered a balanced profile (hardness 113.6 HRR, wear 0.70 g, normal μ = 0.41, hot μ = 0.41), supported by secondary plateau formation. AHP–TOPSIS analysis ranked Lf5 as the optimal alternative (TOPSIS score 0.6438), and sensitivity testing confirmed robustness. Compared with an aftermarket brake pad, Lf5 demonstrated competitive friction stability, wear and hardness value, highlighting its potential as an environmentally responsible brake pad material.