The carbon-ceramic brake disc was developed as a so-called lifetime brake for vehicles. It is not unusual for these brake discs to remain in use for more than 10 years, and in some cases, even up to 24 years. The materials used in the disc itself, silicon carbide, silicon, and carbon are extremely durable and resistant to rust, making ceramic brakes a significant advantage.
However, this durability does not extend to the fasteners that connect the metal adapter for the wheel hub, known as the “bell” with the carbon-ceramic rotor. These metal fasteners are exposed to extreme stress due to high temperatures and corrosion. During intense braking, the brake disc can heat up to over 800 degrees Celsius and cool down quickly afterward. Therefore, the fasteners must be designed to accommodate these thermal expansions. To ensure this, the brake disc is mounted on the hat using a floating mechanism.
Problems arise when the metal sleeves, referred to as “floaters,” embedded in the ceramic material and responsible for transferring braking torque, become corroded. When this happens, the thermal expansion of the floaters can crack the brittle ceramic material, leading to dangerous fractures. These cracks significantly compromise the strength of the brake disc and can have serious safety implications.
To minimize these risks, Rebrake offers professional inspection services for carbon-ceramic brake discs. During this process, the hat and rotor are disassembled, worn screws are replaced with new ones, and corroded bushings are either cleaned or replaced. This ensures the component remains safe and functional. Such inspections are strongly recommended for brake discs older than 10 years and even earlier for vehicles frequently exposed to road salt.