Industrial Brake & Friction Supply (IBFS) is committed to delivering high-performance friction materials for the most demanding applications. This case study highlights the testing and validation of IBFS P208C, a wet friction material specifically developed for heavy-duty brake systems used on Caterpillar and Komatsu haul trucks.

Objective

The objective of this project was to develop a friction material that delivers:

• Superior braking torque and consistency

• Lower thermal fade and better temperature stability

• Extended wear life under extreme load conditions

The goal was to exceed the performance of standard OEM materials commonly used in large off-highway trucks operating in harsh mining and construction environments.

Test Overview

A comparative dynamometer test was conducted between the new P208C material and a leading OEM reference disc. The test simulated repeated brake engagements under controlled thermal and load conditions typical of haul truck applications.

Test Highlights:

• Cycles: 25 sequential high-energy stops

• Initial Surface Temp: ~85°C

• Surface Energy Per Cycle: ~14,000–15,000 J

• Speed: 500 RPM

• Oil Cooling: Constant monitored transmission fluid

The below graphs demonstrate the friction characteristics of both materials.

The below graphs demonstrate the Dynamic torque trace (@120℃, 1.0Mpa) of both materials and their performance after 200, 1000 and 2000 cycles.

The below graphs demonstrate the Static torque trace-break away (@120℃, 1.0Mpa) of both materials and their performance after 200, 1000 and 2000 cycles.

IBFS P208C vs. OEM Carbon Paper – Key Results:

• Higher Torque Output
  → Delivers ~715 Nm vs. ~670 Nm from standard OEM paper.

• Superior Torque Consistency
  → Maintains high stability under repeated load cycles.

• Lower Operating Temperatures
  → Runs cooler (~120–135°C) compared to OEM (~130–145°C), reducing thermal stress.

• Excellent Fade Resistance
  → Performs reliably under high-temperature, high-duty conditions.

• Reduced Wear Rate
  → Longer lifespan with less material loss over time.

Our carbon paper is engineered with high-quality materials and a precision manufacturing process that delivers greater heat resistance, oil compatibility, and consistent friction performance. As a result, our formulation reduces glazing and uneven wear, resulting in longer service life and improved reliability in demanding applications. This is demonstrated in the below graph. 

Key Findings

• Higher average braking torque across all test cycles

• Improved fade resistance, with minimal torque drop-off under heat

• Lower surface temperatures, showing enhanced thermal stability

• Reduced wear, suggesting longer service life in field conditions

These results confirm that IBFS P208C is a robust, high-performance friction solution suitable for wet brake applications in Caterpillar and Komatsu haul trucks.

Conclusion

The results of this comparative dynamometer test clearly validate IBFS P208C as a superior wet friction material for heavy-duty braking systems in haul truck applications. Across every key performance metric: braking torque, fade resistance, thermal stability, and wear rate, P208C outperforms the benchmark OEM carbon paper.

By delivering higher and more consistent torque output, P208C ensures better vehicle control and braking reliability over extended duty cycles. Its ability to operate at lower surface temperatures translates into reduced thermal stress on the braking system, which contributes to longer service life and lower maintenance intervals. The improved resistance to fade, even under repeated high-energy stops, confirms its suitability for demanding off-highway environments like mining and large-scale earthmoving.

Furthermore, P208C’s compatibility with existing steel mating plates eliminates the need for additional component changes or rework during installation, offering a direct-fit alternative with clear performance advantages.

For fleet operators, rebuilders, and OEM-alternative parts suppliers, P208C offers a high-value solution: reducing total cost of ownership while enhancing safety, equipment uptime, and braking system longevity. Based on this robust test performance, P208C is an ideal friction material for haul truck applications operating in aggressive field conditions.