In general, brake linings that are often used contain asbestos materials. This research aims to develop composite-based environmentally friendly brake linings using phenolic resin as a matrix and reinforcement consisting of aluminum powder, brass, silica sand, and bagasse ash. The process of making brake linings is carried out using the powder metallurgy method, which includes the mixing stage using a ball mill and process parameters are used which include Ball Powder weight Ratio (BPR) parameters of 10:1, engine speed of 90 rpm and grinding time of 4 hours. Cold compaction process with varying pressures (5000, 5300, and 5600 Psi), and sintering at 60°C for 10 minutes. The matrix and reinforcement composition variations used were 42%, 50%, and 58% by weight. Tests were conducted on hardness properties using the Brinell Hardness test and density using the Archimedes ASTMB962-17 method. The results showed that variations in compaction pressure and matrix percentage had an effect on hardness. In this test obtained at 42% matrix composition and 5000 Psi compaction pressure with a hardness value that meets the standard of composite brake lining, namely 57 HRB, but has not met the density standard. While at 58% matrix composition and 5600 PSi compaction pressure has a density value that almost meets the standard of 1.467 g/cm3, but the hardness value exceeds the standard of 77 HRB.
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