High Heat-fade Resistance, Metal-free Resin-based Brake Pads: A Step towards Replacing Copper by Using Andalusite

• Andalusite effectively replaces copper in resin-based brake pads, achieving high heat-fade resistance and environmental friendliness. • Optimal tribological performance is achieved with 320 mesh andalusite at 20% content, balancing hardness, impact strength, and wear resistance. • Andalusite addition enhances thermal stability, hardness, impact strength, and density of brake pads, improving medium-to-high temperature friction coefficient. • This study provides a viable path to eliminate copper from brake pads, reducing environmental pollution without compromising performance.