LAUSR

Abstract Designing and developing composites with excellent mechanical, friction, and durability properties at low cost has long been highly desirable for the applications of friction materials. Herein, we employed a cost-effective method to obtain bio-based silica (RHC-SiO2) from gasified rice husk carbon (RHC). Subsequently, inspired by the characteristics of RHC-SiO2 and its hardening process, we report a simple and efficient so-called “hybrid pressing and sintering molding” method for manufacturing copper-based friction materials (CFMs). The CFM-R4 (CFM with 4% RHC-SiO2) possesses a unique combination of high hardness (55.50 H V), low density (0.62 g/cm3), low wear rate (0.081%), suitable friction coefficient (0.26), and good durability. Based on the cost-effective method, the increased and decreased stages of RHC-SiO2 yield were determined mainly by reaction rate and compatibility, respectively. Compared with CFM-0 (CFM without SiO2), the CFM with RHC-SiO2 possesses better mechanical and friction properties. In view of high-performance and eco-friendly, such CFM with RHC-SiO2 would hold a promising application in friction fields such as transmission, differential, and synchronizer.