Brake fade is a reduction in braking effectiveness caused by excessive heat. As friction surfaces overheat, the friction coefficient can drop, resins may outgas (in some materials), and thermal expansion can change clearances. The result is longer stopping distances, reduced holding capability, or inconsistent braking—especially dangerous on hoists and downhill conveyors.
Preventing fade starts with correct selection: ensure the brake has adequate thermal capacity for your duty cycle (stops per hour, stopping energy, ambient temperature). Choose suitable friction materials for high temperatures (semi-metallic or sintered options for extreme duty) and design for heat dissipation—disc brakes often have an advantage here.
Operationally, avoid repeated hard stops when a controlled deceleration is possible. Inspect for dragging brakes, misadjusted clearances, contaminated linings, and worn components, all of which generate extra heat. In high-duty systems, consider two-stage braking or system-level controls to reduce peak energy at the brake. Good maintenance is a fade-prevention tool.
