Browse Publications Technical Papers 2024-01-3044
2024-09-08

Enhancing Brake Performance: FNC-Smart-ONC® Technology to address corrosion challenges and extend the durability of GCI rotors. 2024-01-3044

The most used rotor material is gray cast iron (GCI), known for its susceptibility to corrosion. The impact of corrosion on the braking system is paramount, affecting both braking performance and the emission of particulate matter. The issue becomes more severe, especially when the brakes are left stationary or unused for extended durations in humid conditions, as seen with electric vehicles. Brake disc corrosion not only diminishes braking effectiveness but also amplifies the risk of corrosion adhesion between contacting surfaces, leading to substantial damage and an increase in the quantity and mass of non-exhaust particulate emissions. The friction material of brake pads plays a crucial role in generating the necessary stopping force, creating friction that transforms kinetic energy into heat. However, heightened pressure during braking elevates rotor temperatures, contributing to the degradation of the friction material. This degradation manifests in decreased mechanical strength, heightened pad-to-rotor force, wear, and reduced braking efficiency. To address these challenges and meet the stringent Euro7 particulate emission standards, Nitrex, a leading provider of heat-treating equipment and services specializing in nitriding processes, has developed controlled wear-resistant nitrocarburized layers on cast iron surfaces. These layers offer customizable thicknesses, compositions, and porosity to meet specific requirements. Additionally, Nitrex's latest breakthrough involves the development of a new generation of post-oxidized layers, referred to as Smart-ONC®, known for their remarkable "self-healing" capabilities. These layers formed through a controlled, in-situ post-oxidation process by incorporating additional metals into the oxide layer to enhance corrosion resistance and fortify the surface against damage and potential failures. Dyno tests validate the integrity of the compound layer, affirming its ability to preserve mechanical properties without experiencing wear, delamination, or cracking. Notably, FNC-Smart ONC® discs demonstrate pad material accumulation, serving as a protective interface between pads and discs, effectively sustaining braking performance without extending stopping distances.

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