Enhanced Mechanical Performance and Friction Stability of Modified Phenolic Resin Composites via Nano‐ SiC Reinforcement

ABSTRACT

Phenolic resin‐based friction materials are widely used in braking but often experience friction fluctuations, wear, and thermal degradation under extreme conditions. Nano‐silicon carbide (nano‐SiC) fillers offer high hardness, thermal conductivity, and stability, thereby improving wear resistance and friction stability. In this study, nano‐SiC‐filled phenolic resin‐based friction materials were prepared using a dry process and one‐step hot‐pressing. The effects of nano‐SiC content on mechanical properties, friction, wear performance, wear mechanisms, and thermal fade resistance were systematically investigated. Nano‐SiC significantly enhanced compressive strength and modulus by 66.0% (from 32.9 to 54.6 MPa) and 29.6% (from 890.3 to 1154.2 MPa), respectively. Meanwhile, hardness peaked at 81.0 HRR, and impact strength remained stable within a narrow range (4.11–4.43 kJ/m ² ). In terms of tribological performance, the coefficient of friction increased with nano‐SiC content and braking velocity, reaching approximately 0.47. Notably, the 2 wt.% specimen achieved a 76.0% reduction in volume wear rate (from 0.102 to 0.024 cm ³ /MJ), while the 1 wt.% content provided optimal friction stability. Mechanism analysis revealed that nano‐SiC promoted the formation of a continuous friction film; with the addition of nano‐SiC, the dominant wear mechanism transitioned from fatigue wear and abrasive wear to abrasive wear and adhesive wear.