A basalt-based automobile brake pad was developed through optimization of the volume fractions and manufacturing parameters, a mathematical model was developed based on rule of mixture for the optimization of the volume fraction and the solution obtained using excel solver is as follow; basalt 38%, cast iron chips 26%, bronze 12%, glass fibre 12% and phenolic resin 12%. The manufacturing parameters were design using full factorial design of three levels and three factors, twenty-seven runs were obtained from the design, consequently twenty-seven samples were produced by compression moulding. The constituent materials were properly mixed to obtained homogeneous mixture and compressed into a mould with a cavity similar to the shape of the friction pad this was done at different moulding pressures of 30MPa, 27MPa and 24MPa, the curing temperatures were 1800C, 2000C and 2200C and the curing of 5minutes, 10minutes and 15 minutes as obtained from the factorial design. The samples produced were subjected to tests, the results showed that the basalt brake pad has the following properties; compressive strength of 137mPa, coefficient of friction 0.476, hardness 70HRB, density of 2768kg/m3 thermal conductivity of 0.66W/mK, water absorption of 0.377%, oil absorption of 0.25%, void content of 18.93%, wear rate of 9.0X10 -4g/m and the TGA result shows that the basalt-based brake pad is thermally stable up to a temperature of 5000C. The properties of the basalt-based brake pad are within the acceptable range and can satisfactorily substitute basalt.
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