Modern sports cars and high-performance vehicles with a sporty focus are increasingly being equipped with carbon-ceramic brake systems at the factory. The advantages of these brake systems are their lower weight and better braking performance. However, they are also more expensive than conventional steel brake systems. If they need to be replaced due to damage or wear, vehicle owners can expect high costs. This can quickly lead to costs exceeding €30,000.
Rebrake GmbH has developed a process that makes it possible to recondition a worn carbon-ceramic brake disc. Minor mechanical damages, which often occur during tire changes, can also be repaired. From a cost perspective, reconditioning is very appealing, allowing the customer to save up to €5,000 per brake disc, or even up to €20,000 if all four brake discs are affected by wear or damage.
After a lot of braking and/or hard use on the racetrack, the surface of the brake disc, also known as the friction layer, gets destroyed. However, the core (which makes up 95% of the volume) remains undamaged and can still be used.
Rebrake is able to renew this friction layer, thus restore the brake disc to an almost new condition.
This is done by preparing the damaged surface mechanically and thermally for coating. The coating is applied by depositing the carbon/silicon carbide-containing material onto the surface. In a high-temperature step in a vacuum atmosphere, a reactive bond is formed between the new friction layer and the supporting body through the addition of silicon. This consists of a similar material with comparable composition and hardness to the original friction layer. After restoring the surface condition through a precise fine grinding that meets the manufacturer’s tolerances, the brake disc can be used safely and permanently again. Rebrake has developed and patented this process in collaboration with LCT and under the direction of Prof. Dr. Walter Krenkel (formerly of the University of Bayreuth).”
This process is also beneficial for our environment. The ceramic brake disc is already a very durable and eco-friendly product. Through reconditioning (remanufacturing), 95% of the disc is preserved and it only requires about 10% of the energy needed to produce a new disc. The same applies to the raw materials required, making reconditioning extremely environmentally friendly and resource-efficient.
Rebrake Ceramic Service GmbH, Bayreuth, January 30, 2024