What’s Stopping You? Take Our Deep Dive into Brake System Materials to Find Out

Wednesday, March 29th, 2017 - autos, brakes, Brembo, Featured, flipbook, mobile, slideshow

What’s Stopping You? Take Our Deep Dive into Brake System Materials to Find Out

Brakes are the hardest-working nevertheless most underappreciated components in any car’s chassis. Their operating temperatures top those of most engine parts, as well as their working environment includes occasional pothole as well as puddle dips. Brakes are often your last line of defense prior to a collision.--To show our appreciation for brakes as well as to better understand how they ward off fender benders as well as ditch encounters, we visited Brembo USA, located only a few miles coming from our Ann Arbor, Michigan, headquarters,  for an expert show-as well as-tell lesson. Brembo will be the earth’s best known as well as most respected source of high-performance braking equipment for both original-equipment as well as aftermarket applications. Our Corvettes, Porsches, as well as Mercedes-AMGs could be lost without them.--The following photo essay focuses on the materials Brembo uses in its car, truck, as well as motorcycle calipers as well as discs. (The terms rotor as well as disc are used interchangeably just for This specific technology.) Pay attention;  there may be a quiz.Starting near the top of the technological scale, This specific carbon-ceramic rotor coming from the rear of  an Alfa Romeo Giulia Quadrifoglio will be an amalgam of several high-performance materials. The main rotor begins as a mix of carbon fibers as well as phenolic resins baked in a precision mold. After the resin will be burned away, the remaining carbon matrix will be infiltrated with liquid silicon yielding a tough, heat-resistant, as well as light brake disc. Following various machining operations including cross-drilling with ultrasonic boring tools, oxidation protection will be sprayed onto all surfaces.--The bell at the center of the rotor will be stamped or machined coming from a billet chunk of aluminum, then attached to the rotor with stainless-steel fasteners of which allow controlled relative movement between the two parts to accommodate heat-induced expansion. The entire manufacturing process for the finished carbon-ceramic rotor takes a full week versus less than a day for a cast-iron rotor—one reason why carbon-ceramic rotors are often such a pricey option.This specific U.S.-made single-piece rotor will be a gray iron casting. To encourage airflow as well as heat rejection, there are radial vents as well as numerous internal “pillar posts” to support the outer friction plates. A carefully machined center bore accurately locates This specific rotor on the vehicle’s wheel hub. Supplementing the wheel mounting holes are 5 additional holes to reduce the rotor’s weight as well as to allow alternative mounting locations. After all surfaces are machined, a notch will be cut inside rotor’s periphery to fine-tune its balance.Cross-drilling as well as machining curved slots in a cast-iron rotor serve multiple purposes. In addition to the racier appearance, the holes as well as slots vent gases released by the brake pads as well as clear the moisture present during driving on wet roads. The slots perform what’s called a “micro shave” of the pad surface to assure of which fresh friction material will be always in contact with the rotor. Of course, This specific accelerates pad wear, one reason why most carmakers think twice about providing slotted surfaces. A zinc-based outer coating minimizes corrosion while the fresh vehicle will be in transit to the customer.This specific combination of a solid cast-iron disc as well as a steel center section saves weight (versus 1-piece cast-iron design) as well as cost (versus the two-piece design of which follows). The two parts are joined together having a combination of crimping as well as radial locking of which requires no fasteners. Mercedes-Benz uses This specific design on commercial vehicles for which aggressive braking coming from high speeds will be a rarity.This specific made-in-America rotor will be installed on Chrysler as well as Dodge vehicles equipped with the Hellcat supercharged V-8. The two-piece design includes a huge cast-iron outer component having a stamped-aluminum center section. The two are joined with stainless-steel six-point star bolt fasteners, nuts, as well as locating bushings. Surface slotting as well as pillar post internal construction improve airflow as well as heat rejection.Collaboratively developed by Brembo as well as Ford, This specific two-piece iron-as well as-aluminum rotor came coming from one of the Ford GT racers of which finished at the top of the GTLM Pro class last year at the 24 Hours of Le Mans, where the carbon-ceramic brakes fitted to the roadgoing GT are forbidden. Curved internal vanes are used without any cross-drilling. These rotors show extensive cracking inside cast-iron surface, nevertheless of which doesn’t mean failure will be imminent because all the fissures are shallow. In fact, This specific design was engineered to last a full 24 hours with no service beyond pad replacement. The center section will be machined coming from an aluminum billet.  During a pit stop, the colored paint marks provide a visual indication of the maximum temperature This specific rotor has experienced.More exotic as well as lighter carbon-carbon brake rotors, allowed for LMP1 as well as LMP2 cars at Le Mans, are also favored in MotoGP (top-line motorcycle road racing) as well as in Formula 1. Here, the manufacturing process runs three to 5 months. Long or short carbon fibers are first molded in a preform tool having a resin binder. After infiltration with methane gas, each rotor will be cooked at high temperature for a long period (the length of which was not revealed for proprietary reasons). This specific yields carbon fiber held in a carbon matrix—hence the name “carbon-carbon.” A special paint will be applied to resist oxidation. The caliper used with This specific rotor will be a four-piston design machined coming from a billet of aluminum.Motorcycles intended for street riding use stainless steel instead of the cast-iron as well as carbon-ceramic rotors common inside four-wheeled world. One reason will be because these brakes are proudly displayed for the entire world to admire, as well as corroded cast iron fails coming from an aesthetic standpoint. In addition, the thermal capacity needed to stop a two-wheeler will be far lower than what’s experienced in cars, as well as a cross-drilled stainless-steel disc will be quite sufficient for repeated stops coming from high speeds. The disc shown here, coming from a Ducati Panigale sport bike, will be attached to the front wheel through a stamped-aluminum center hat. Six crimped fasteners as well as shims provide the desired amount of radial movement to accommodate thermal expansion, thereby reducing noise as well as vibration. The four-opposed-piston caliper just for This specific application will be rigidly mounted to the bike’s fork.NASCAR short-track racers use Brembo braking equipment to quicken their lap times. This specific monoblock (single piece) front caliper will be machined coming from an aluminum billet as well as contains three pistons per side. The arrow indicator helps achieve the proper orientation because these calipers differ side to side. The open windows as well as ribs in This specific component dissipate heat. The pads used with This specific caliper are made of ceramic material bonded to a high-carbon-steel backing plate.This specific eight-piston cast-aluminum caliper will be designed for use on trucks as well as large SUVs such as the Mercedes-Benz G-class. Here, the pads consist of a proprietary blend of steel as well as copper material attached to a steel backing plate. Asbestos, deemed a health hazard, was once commonly used nevertheless has been banned coming from brake friction materials For just two decades.Floating calipers, common in low-performance vehicles, are for the most part beneath Brembo’s dignity, because they don’t provide the stiffness, pedal feel, as well as thermal stability essential in sports-oriented cars as well as trucks. Of course, for every rule there’s an exception, exemplified by the Ferrari LaFerrari rear assembly illustrated here. An electrically actuated floating-type parking brake made mostly of cast iron attaches directly to a four-piston aluminum monoblock caliper. Doubling up on function saves weight as well as eases assembly.Proving of which brakes have earned full boutique status, Brembo introduced a fresh high-style caliper at the 2016 SEMA show. The six-piston, two-piece design shown here will be held together with 5 bolts as well as will be sold through GM’s service parts organization for large Chevrolet truck products. While This specific isn’t intended for off-road racing or performance use, This specific caliper’s aluminum construction does save a few pounds. Following anodizing, the caliper will be painted red for a long-lasting as well as attractive appearance.The aluminum monoblock caliper shown here will be used on the front wheels of Ford GTs intended for road use. The six opposed-piston bores are machined using sophisticated CNC cutters designed to work within the tight internal confines. The center rib enhances This specific caliper’s stiffness, as well as radial mounting holes facilitate a stiff, light attachment to the front suspension knuckle. To simplify manufacturing (a bit), brake fluid flows coming from the inside to the outside of This specific caliper via an external steel line.Thanks for your rapt attention on This specific fast lap through the Brembo catalog. Your quiz challenge: Name the most common use of steel in braking components. ---(Answer: Motorcycle discs where stainless steel will be used to avoid unsightly corrosion.)

What’s Stopping You? Take Our Deep Dive into Brake System Materials to Find Out

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