Material wear of the friction layer caused by normal braking operation, down to the wear limit.

Cause:
Abrasive wear is caused by continuous friction between the brake pad and the brake disc. As a result, the friction layer of the carbon-ceramic brake disc is gradually worn away over time. This process is normal and inherent to the design, but as mileage increases, it leads to a measurable reduction in the thickness of the friction layer.

Typically, wear affects the top layer of the brake disc to a depth of about 1–1.5 mm, while the structural core of the disc generally remains undamaged.

If a certain wear limit is exceeded, the brake disc’s performance can no longer be fully guaranteed. This can lead to reduced friction, uneven braking performance, or thermal overload, and thus poses a safety hazard.

Repair:
As part of the repair process, the worn friction layer is completely removed and the surface is specifically prepared for rebuilding. The friction layer is then rebuilt using a high-temperature process (liquid silicidation), which creates a new, high-strength Si/SiC friction layer.

The reactive bond with the substrate creates a permanently adherent and highly durable surface with excellent friction and wear properties.
Since the load-bearing core of the brake disc is preserved in most cases, the disc can be fully remanufactured and restored to like-new condition. Its mechanical and thermal properties match those of a new brake disc or may even exceed them in certain areas.

Mechanical chipping at the edges or on the surface that exposes the substrate and promotes oxidation.

Cause:
Edge and surface damage is caused by mechanical impacts, such as stone chips, improper handling, or foreign objects. Typical signs of damage include chipping along the edge or on the friction surface of the brake disc, which may result in a technical complaint.

A major problem here is the exposed backing material: Without a protective wear layer, the exposed carbon is susceptible to oxidation, which can cause the damage to worsen during continued use.
Such damage is often classified as requiring repair during inspections (e.g., by the TÜV) or according to the vehicle manufacturer’s specifications.

Repair:
Damaged areas are filled locally with a silicon-based material. This is followed by pyrolysis under controlled conditions, which restores the structural bond with the base material.

This process prevents secondary damage such as cracking or further material delamination and restores the structural integrity and operational safety of the brake disc.

The brake disc is then resurfaced to ensure a uniform surface. Minor repair areas are usually barely visible afterward, and the necessary protection against oxidation is fully restored.

Uneven wear causes the brake disc to become warped, resulting in noticeable vibrations when braking.

Cause:
Vibrations during braking are often caused by uneven wear of the friction layer, which results in the brake disc no longer being flat and parallel. This type of wear is particularly common in carbon-ceramic brake discs (e.g., Audi’s CCB systems) and leads to what is known as thickness variation or out-of-roundness.

Due to the uneven surface, the brake pad no longer makes even contact with the brake rotor. This causes fluctuating friction forces during braking, which result in noticeable vibrations in the steering wheel and brake pedal.

Repair:
To repair the damage, the brake disc is first removed and disassembled into its individual components. Then, both the friction rings and all fasteners are thoroughly cleaned and inspected.

After professional reassembly, the friction surfaces are machined with precision. The brake disc is ground to be flat and parallel in accordance with the manufacturer’s specifications, thereby restoring an even contact surface for the brake pads.

This process eliminates vibrations and fully restores the original braking performance.

Fasteners that are corroded or damaged restrict movement and can cause noise or cracks.

Cause:
Contact corrosion, thermal stress, or material fatigue can damage fasteners such as screw connections and so-called “floaters” or render them unusable. In many cases, these fasteners become firmly corroded in the area where they come into contact with the ceramic material and lose their mobility.

Floaters are essential to the proper functioning of the brake disc, as they must evenly transfer torque from the disc to the wheel hub while compensating for thermal expansion. If this mobility (“floating”) is restricted or no longer present, it can lead to uneven stress distribution and, in the worst case, cracking of the material.

In addition, defects in fasteners often manifest themselves as noises during operation.

Repair:

Damaged or severely corroded fasteners are professionally removed and replaced with new components. In particular, the floaters are replaced to fully restore the necessary mobility and functionality.

Replacing these components can significantly extend the service life of the brake disc and ensure its long-term operational safety.

We also offer matching bolt-on and floater sets for a wide range of brake disc types. We would be happy to review your request on a case-by-case basis and put together the appropriate components for your system.