This article investigates into the physical and thermo mechanical properties of a friction composite material based on ox horn and phenolic resin. The tests revealed that an intermediate density of 100 μm offers a good balance between density and homogeneity. Increasing the horn particles fraction reduces the density of the composite, thereby influencing its compactness and porosity. Scanning electron microscopy (SEM) and transmission electron microscopy (TEM) morphology analysis revealed that fine particles (50 μm) provide good dispersion and promote porosity. Intermediate particles (100 μm) offer the best balance of cohesion, low porosity and good mechanical performance. Coarse particles (300 μm) provide greater density but less effective interfacial adhesion. The compressive strength of the composite depends heavily on particle size and horn particles fraction. The static friction coefficient of the horn particles and phenolic resin composite (100 μm) is 0.42/0.35 (for Kevlar-based brake linings) and 0.40 (for carbon fibre-based linings). Wear tests have proven that the ox horn and phenolic resin composite varies between 2.5 - 3.0 (mm3/Nm) and 1.5 - 2.0 (mm3/Nm).
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