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This study aims to investigate the effect of different volume percentage (Vol.%) of steel fibre on the pressure, surface temperature and speed sensitivity behaviour during braking process as known brake effectiveness and to propose the best steel fibre Vol.% in the formulation.

Three brake pads composed of three different steel fibre volume percentages were fabricated through powder metallurgy route. Selecting one sample as based formulations, steel fibre (Vol.%) was decreased and increased by 50 per cent in the other two samples, respectively. The other ingredients are proportionally increased and decreased accordingly to the base formulation. The samples were tested for determining their hardness, porosity and coefficient of friction (COF) using Rockwell hardness tester, hot bath and brake inertia dynamometer, respectively.

Test results indicated that Sample T1 which composed of 9 Vol.% of steel fibre had the lowest COF and was sensitive to applied pressure, surface temperature and speed. The samples which composed of 18 and 27 Vol.% of steel fibre were having the same trend of COF and were sensitive to surface temperature and speed. Sample T which composed of 18 Vol.% of steel fibre had lower brake pad and disc lost as compared to Sample T2 which composed of 27 Vol.%. Mechanical properties did not show any significant correlation with COF sensitivity with temperature, speed and pressure.

The sample with 18 Vol.% of steel fibre was found to be the best formulation which produced acceptable COF; less sensitive to temperature, pressure and speed during braking process; and better wear resistance of brake pad as well as the rotor.