Abstract: Disc brakes are vital for automotive safety, and they work by transforming kinetic energy into heat via friction to slow or halt vehicles. Here, we review disc brake research, with regards to thermal performance, structural integrity, material selection, noise-vibration-harshness (NVH) behaviour, etc. They focus on thermal management methods, like ventilated disc designs and materials that help dissipate heat. A structural analysis, mainly finite element analysis (FEA), is presented to quantify stress distribution and fatigue due to braking loads. Conventional and advanced materials are examined, including their mechanical durability, thermal characteristics, and environmental sustainability — including grey cast iron, stainless steel, carbon ceramic composites and aluminium alloys. The study also addresses NVH aspects and reasons of squeal and judder besides discussing numerical methods for prediction and prevention of these annoyances. It provides final suggestions for combined simulations, green materials and the new designs to enhance overall capabilities of the disc brake. Future research directions underscore enhancements in performance, cost-effective innovative approaches, and environmental sustainability in next generation braking systems.

| DOI: 10.17148/IARJSET.2025.12341