Aluminum Ceramic Brake Disc (Aluminum matrix composite with varying SiC volume fractions)

Shandong Zonxin Auto Parts Co., Ltd. was the first to apply aluminum‑ceramic brake discs to commercial vehicles and optimized the connection method between the brake disc and the hub. Aluminum‑ceramic brake discs are lightweight, wear‑resistant, corrosion‑resistant, and have a long service life, significantly outperforming traditional HT250 cast iron brake discs.

1) Material

Aluminum‑ceramic (an aluminum‑based composite with varying silicon carbide volume fractions) replaces HT250 (cast iron).

The raw materials for aluminum‑ceramic brake discs are aluminum powder and silicon carbide powder, formed and sintered by powder metallurgy processes and then machined.

2) Structure

The traditional I‑section (I‑beam) disc structure was changed to a flat disc structure to reduce material usage and weight. This domestic innovation has obtained 1 national utility model patent.

3) Process

Mixing → mold pressing → sintering → shaping → rough machining → finish machining → inspection

The powder metallurgy process controls different sintering temperatures at different stages to enhance material mechanical properties.

4) Assembly

The aluminum‑ceramic brake disc is fastened to the hub flange surface by guide sleeves and bolts, effectively reducing the vertical overlapping portion of traditional I‑section discs.

5)  Performance Indicators

Static torsional strength: Under a braking torque load of 22,000 Nm, the maximum stress is 112 MPa; the inner surface of the connection holes also experiences 112 MPa. At 260°C the safety margin is 1.2.

6) Wear, Corrosion, and Service Life

Aluminum‑ceramic brake discs wear 0.08 mm per 10,000 km, a 72% reduction compared to HT250 cast iron discs (0.28 mm/10,000 km), meeting Euro 7 requirements. Service life is approximately 500,000 km—an increase of 235% compared with HT250 discs (~150,000 km). Using a maintenance‑free installation process, maintenance‑free mileage reaches 300,000 km, a 500% improvement over HT250 discs. Salt spray tests (72 h) show only slight corrosion.

7)Weight

Total vehicle weight savings for aluminum‑ceramic brake discs: 117 kg (based on a 13T three disc‑axle semi‑trailer).

8) Temperature Performance

According to GB12676‑2014 'Technical Requirements and Test Methods for Brake Systems of Commercial Vehicles and Trailers', under continuous 20 braking cycles with a braking interval of 60 s, initial speed 60 km/h, and braking deceleration set to 3 m/s²:
• Unloaded (empty): maximum temperature 75°C
• 40% load: maximum temperature 204°C
• 50% load: maximum temperature 246°C
• Fully loaded: maximum temperature 510°C
Using aluminum‑ceramic brake discs, the wheel end temperature rises by only ~30°C above ambient—significantly better than traditional hubs which rise by ~60°C—reducing wheel end temperatures by 50%. This substantially reduces the safety risks caused by wheel end overheating and prevents brake disc high‑temperature cracking when sprayed with water and wheel end fires.

9) Product Benefits

Assuming a semi‑trailer transport cost of approximately RMB 0.35 per ton‑km, a daily driving distance of about 450 km, and an annual utilization of about 300 days, a three‑axle semi‑trailer equipped with aluminum‑ceramic brake discs can reduce vehicle weight by 117 kg per vehicle and achieve additional income of approximately RMB 4,000 per year. Over the full service life of aluminum‑ceramic discs, brake disc replacements can be reduced by two times. For each replacement, labor savings amount to 150 × 6 = RMB 900, parts savings 300 × 6 = RMB 1,800, and parking/replacement downtime loss is approximately RMB 1,400. Two replacements combined save about RMB 8,200. Overall, each vehicle can increase customer benefit by approximately RMB 12,000 per year.