Advances in brake friction materials: A comprehensive review of ingredients, processing methods, and performance characteristics

Abstract The crucial significance of brake friction materials lies in ensuring automobile safety and performance. This drives the ongoing development of these materials to meet rigorous criteria. Recent developments in friction materials have improved the effectiveness of braking systems, resulting in increased safety and comfort. Modern society has increasingly adopted environmentally friendly friction materials, replacing conventional alternatives. The advancements in brake friction material development primarily focus on improving braking performance while simultaneously reducing environmental pollution caused by dangerous substances in brake pads. Understanding the different formulations of brake pads and the impact of the materials used is essential due to the complex and expert‐dependent nature of the brake pad manufacturing process. This review aims to fill knowledge gaps surrounding the basic formulations of brake pads and provide insights to researchers on the impact of different ingredients in creating friction brake pads. This research not only highlights the influence of various components on the friction and wear characteristics of brake pads but also addresses the importance of a comprehensive understanding of their fundamentals. The novelty of this review is justified by the lack of up‐to‐date, thorough reviews on brake friction materials, particularly in light of the recent advancements in the field. This review focuses on the developments and innovations in brake friction materials over the last 15 years. It aims to bridge the knowledge gaps regarding the basic formulations of brake pads and provide valuable insights into the influence of various components on their friction and wear characteristics. By addressing both the performance improvements and environmental considerations, this review offers a timely and essential resource for researchers and practitioners in the automotive industry. Highlights Exploration of various ingredients used in the brake friction composites. Ingredients influence on the various characteristics of brake friction composites. Different formulations and its usage in the brake friction composites. Recycled materials usage in the friction composites‐waste to wealth approach.