Brembo SGL carbon ceramic brakes

Brembo SGL Carbon Ceramic Brakes (BSCCB) specialize in the design, development and manufacturing of carbon ceramic braking systems for high performance vehicles.

BSCCB are also active in the research and development of new materials, composites and applications.

The BSCCB company has two manufacturing plants for producing carbon ceramic brake discs, one located in Stezzano, Italy and other in Meitingen, Germany.

Material

A special feature of BSCCB carbon ceramic brake discs is the ceramic composite material and additional friction layer on both sides of the braking surfaces. The core and friction layers consist of composite materials made of carbon fibers (reinforcement) silicon carbide and metallic silicon (matrix).

Silicon carbide, the main matrix component, creates a solid surface for the composite material. These carbon fibers provide high mechanical strength and the fracture resistance needed in these technical applications.

Phenolic resin and carbon fibre

The resulting quasiductile properties of the ceramic composite material combine the properties of carbon fiber-reinforced carbon (C/C) and polychrystalline silicon carbide ceramics. The elongation of ceramic matrix composite (C/SiC) materials ranges from 0.1 to 0.3 %. This is exceptionally high for ceramics.

This profile makes fiber-reinforced silicon carbide an ideal-choice for high-performance braking systems: resulting in low weight and stable characteristics under extreme pressure and temperature. The resistance to thermal shock and the quasiductility provides long-term durability.

Silicon

Production steps

The carbon-ceramic brake disc has a production process of approximately 20 days. During this process, carbon fibers are given a special protective coating and then cut into short fiber sections of defined thickness and length. The fiber can be used in this form or treated further to create a complex material called “carbochip”.

The production process starts with a mixture of the component and ends with the complete assembly. The production of the ceramic brake body requires a preformed press with binding resin. This is converted in the ceramic component by carbonization at 900 °C and then by siliconization at 1700 °C in high vacuum.

Production cycle

One of the complex features of the manufacturing process is the use of “lost core” technology – a plastics matrix which defines the design of the cooling channel geometry without residues at carbonizination.

Another complex feature is the use of different fiber brake body components. The friction layers on the ring (exterior side) and the point-shaped abrasion indicators are integrated into the friction layer. With such high degrees of material hardness, high-tech diamond tooling methods are utilised to complete the machining process.

Brake portfolio

Carbon Ceramic Brake – CCB 

A floating brake disc with a core of ceramic material (reinforced with carbon fiber), with an additional ceramic layer on both friction surfaces.

Applications: VW, Porsche, Audi, Bentley, Lamborghini, Bugatti, AMG.

Ceramic Composite Material – CCM 

A floating brake disc composed of carbon fiber in ceramic matrix.

Applications: Ferrari, Maserati, Aston Martin, Pagani, McLaren.

Ceramic Matrix Composite – CMC

A floating brake disc of ceramic reinforced material with an additional ceramic layer on both sides of the braking surfaces.

Application: McLaren SLR.

Key advantages of carbon ceramic discs

The key advantages of BSCCB carbon ceramic discs (compared to cast iron brake discs) include:

        • Lower weight
        • Longer lifetime
        • Higher thermal stability
        • No judder
        • Higher friction coefficient stability
        • Improved handling due to reduction of rotating unsprung mass
        • Corrosion resistance
        • Reduced brake dust
        • Higher performance 

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