Laboratory

Illustrations show internally ventilated grey cast iron brake disc (semi-finished product) with C4INOXit® coating. Development status 07/2020.

Contact surface and cup bottom not coated (partial coating). Fan duct cut open radially.

Homogeneous and, with regard to layer thickness, uniform application of the coating material over the entire coating surface. Coating thickness is thicker on the friction surface than in the ventilation channel. Interior of the ventilation channel completely coated and "slipstream-free".

Microsection of the inner area of the ventilation channel with a diffusion depth of 0.12-0.15 mm. The diffusion depth is uniform over the entire width of the ventilation channel. Due to the lack of mechanical stress on the ventilation channel, the existing diffusion depth is considered optimal.

The diagram shows the hardness curve of the friction surface layer structure. In this test specimen, the hardness on the finally machined surface starts at 682 HV and increases to a diffusion depth of 0.21 mm to 960 HV. This hardness curve exists on both sides of the friction surface. The hardness curve is homogeneous over the entire friction surface with the characteristics shown.

AK Master

Parameter:

Vehicle data: GVW 2.5 t, Vmax 240 kph / brake disc size 340 internally ventilated / brake pad (ECE, current series) / brake pads with cold compressibility at the lowest limit of the OEM specification / brake (current series) / diffusion depth test specimen = 0.20 mm.

Result:

Fading behavior complies with legal requirements / Performance test shows no abnormalities / No wear up to the diffusion limit reached by test / No change in friction coefficient detectable

AMS 130

(specification according to OEM)

OEM specification / requirement

C4INOXit®

Friction value deviation
5 stops.

< 8%

4%

Pressure Variance

+/- 5%

3%

MFDD per stop

< 10%

6%

Metal Pick Up

< 5%

3%

Fish formation

0%

0%

Contact pattern brake lining

80 - 100%

95%

Scoring brake disc

< 5%

< 5%

Cooling time

< 8000s

6500s

Layer cracks Coating

0%

0%

Edge break coating

< 20%

10%

Parameter:

Vehicle data: GVW 2.5 t, Vmax =240 kph / brake disc size 340 internally ventilated / brake pad (ECE, current series) / brake (current series) / brake pads with cold compressibility at the lowest limit of the OEM specification / diffusion depth test specimen = 0.20 mm

Result:

AMS 130 specifications completely fulfilled / Coefficients of friction are stable over the test run / No abnormalities on brake pads or the surface of the brake disc

Block Wear Test

(specification according to OEM)

OEM specification/
Requirement

Series without coating

Series with C4INOXit® coating

Total wear of brake disc

145 g

134 g

74 g

Total wear of brake pads

3.0 Sets

3.2 Sets

2.5 Sets

Radial oblique wear Brake pads Rim side

< 0,60 mm

0,40 mm

0,40 mm

Tangential oblique wear Brake pads piston side

< 0,90 mm

0,40 mm

0,50 mm

Max. Differential wear of brake pads

0,80 mm

0,25 mm

0,20 mm

Coating assessment

Scoring < 0.5 mm
Surface scoring < 15%
edgebreak max 1,5mm
No coating breakouts
No layer cracks

0,2 mm
5%
0,2 mm
i.O.
i.O.

0,1 mm
3%
0,2 mm
i.O
i.O

Ohne Beschichtung

LMD Beschichtung

INOXIT® Beschichtung

Bremsscheibenverschleiß in Gramm

210

42

74

Bremsbelagverschleiß in Gramm

230

88

114

Parameter:

Vehicle data: GVW = 2.5 t, Vmax = 240 kph / brake disc size 340 internally ventilated, brake pad (ECE, current series) / brake (current series) / brake pads with cold compressibility at the lowest limit of the OEM specification / diffusion depth = 0.20 mm.

Mechanical Strength Test

(specification according to OEM)

Crack Test

(specification according to OEM)

Parameter:

Vehicle data: GVW = 2,5t, Vmax = 240 kph. Brake disc size 340 internally ventilated / brake pad (ECE, current series) / brake (current series) / brake pads with the cold compressibility at the lowest limit of the OEM specification / diffusion depth = 0,20

Result

After 500 cycles no tearing of the friction surface (OEM requirement 450 cycles).

Performance Test

(specifications according to OEM)

Parameter:

Vehicle data: GVW = 2.5 t, Vmax = 180 kph / brake disc size 320, brake pad (ECE, current series) / brake (current series) / brake pads with cold compressibility at the upper limit of OEM specification /diffusion depth = 0.20 mm.

Result:

Condition of the brake disc and brake pads after test very good / Test specimen shows a very stable performance behavior / Fading behavior comparable to a hard material coating / Wear rates per stop with 0.02 mm well below the series (0.05 mm) / Total wear of the brake disc 25g (series = 50 g).

Corrosion Endurance Test

(specification according to OEM)

Parameter:

Vehicle data: GVW = 2.5t, Vmax = 240 kph / brake disc size 340 internally ventilated, brake pad (ECE, current series) / brake (current series) / diffusion depth = 0.20 mm.

Result:

short test. Conditioning and generation of wear grooves (limit load test) / after winter combination test, the friction surface shows the typical corrosion application which is "washable" / ventilation channel and other coated surfaces completely free of corrosion

Note:

Results of a full corrosion endurance test will be published shortly.

Measurement of Damping Factor

(specification according to OEM)

Note:

Test results will be published shortly.

Fine Dust Test

(specification according to OEM)

Note:

Test results will be published shortly.