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CARBON-CERAMIC BRAKE TECHNOLOGY
WHAT ARE CARBON-CERAMIC BRAKES?
While there are several benefits to using carbon and ceramics in brake systems over alternative materials, their production involves much longer and more expensive processes. Is the expense justified by the benefits they provide?
COOL UNDER PRESSURE
The usage of heat-resistant carbon and ceramic-based materials began with the incredibly costly endeavor of space exploration, which may serve as a sign of their ultimate cost.
In order to withstand the friction heat produced during re-entry into the atmosphere, NASA’s space shuttles were coated on the undersides with silica ceramic tiles. Where temperatures were at their maximum, reinforced carbon (RCC) was utilized, most notably on the nose cone and leading wing edges.
The Concorde, an engineering marvel, was the first vehicle to use carbon-carbon (graphite reinforced carbon fiber) components in brake systems in 1976. By the end of that decade, F1 vehicles had adopted their own systems based on the same technology.
WITH OUR POWERS COMBINED
Although employing carbon-carbon brakes has many advantages, there were also some drawbacks that prompted researchers to look into alternate materials.
Carbon-carbon brakes were not suited for use on roads since they performed very poorly in cold or rainy weather. They also didn’t last very long since, when braking, carbon oxidizes at high temperatures, increasing the cost of maintaining the already expensive parts on a car.
Although F1 teams didn’t mind too much, not many people would buy a car that currently requires new rotors every 1000 kilometers at a cost of roughly €10,000 a set.
As a result, carbon-ceramic brakes were created, which combine the durability of ceramics with the majority of the advantages of carbon brakes. The use of silicon carbide improved the brake discs’ ability to withstand thermal shock and oxidation, extending their lifespan and improving their ability to withstand a wider temperature range.
Although they were still pricey, they were at least more suited for some automobile uses. Supercar manufacturers showed interest in ceramic braking technology, but it was initially applied in high-speed rail, which understandably takes the brakes of rapidly moving things very seriously, especially when those objects weigh hundreds of tonnes.
CRAFTED
The production procedure is the sole cause of their high cost. Each brake disc takes the better part of a month to create, therefore the construction process is labor-intensive and time-consuming.
After being poured into molds, a mixture of silicon resin and carbon fiber is heated to 200 degrees Celsius and compressed to 20,000 kg before being cooled.
After adding more silicon powder and heating the mold a third time for a further 24 hours at 1700 degrees Celsius while under vacuum, the mold is heated once more over the course of two days to 1000 degrees Celsius.
Through this procedure, the basic materials that surround the carbon fibers are transformed into the silica carbide ceramic, which increases their longevity and durability.
WHAT WE DO
1. DESIGN
2. MANUFACTURING
3. INSTALLATION
TRONIK AUTOMOTIVE’s brake system design begins with a thorough scan of the vehicle’s wheels to create a highly accurate 3D model. If the selected vehicle model is not in our database, we perform additional analysis and measurements to obtain all the necessary parameters.
We then proceed to calculate the brake system geometry using state-of-the-art Siemens NX software. This allows us to perform detailed simulations, considering factors such as temperature loads, dynamic loads and force distribution. With this approach, we can optimize every element of the braking system for maximum performance and reliability.
Once the design is complete, we begin the process of manufacturing the necessary components for the braking system.
The transition from digital design to physical components is guided by high-precision manufacturing techniques, including computer numerical control (CNC) machining that brings our brake system components designs to life with exacting standards.
Through each stage of our scientifically grounded manufacturing cycle, TRONIK AUTOMOTIVE delivers brake components designed to meet the highest standards of performance and resilience. With every system, our dedication to material science and precision engineering brings drivers the power to stop with confidence, no matter the challenge ahead.
We offer our customers an opportunity to install TRONIK AUTOMOTIVE brake systems at our service station in Dubai. Our qualified specialists begin by assessing your vehicle’s braking architecture, allowing us to tailor the installation to your specific needs.
With precision alignment, we secure the rotor and caliper positioning to eliminate vibrations and ensure even pressure distribution. After the components are meticulously installed, our team conducts thorough testing to guarantee optimal function and responsiveness.
This comprehensive installation process, performed by skilled technicians, ensures your brake system delivers exceptional reliability and safety on every drive.
