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X-ray image of a brake disc

The refurbishing process in detail:

  • After the initial incoming control the discs are weighed and depending on wear and wear pattern the rotors are x-rayed and examined for structural damage.
  • After that any brake pad residue or contaminates is chemically steamed off.
  • The rotors are machined until they are level.
  • The napped are vacuum soaked in polymeric carbon.
  • The next step is to pyrolyze the rotors at 1100°C.
  • The last two steps are repeated three times.
  • Now the discs are siliconized at 1500°C.
  • The top layer (ca. 1mm thick) is now restored, and trough the pyrolysis it is chemically and physically bonded with the structure.
  • Now follows the final sanding of the top layer.
  • The disc is completely reassembled and is weighed once more and precision-balanced.
  • The disc now has gained about 30-50g and is at desired value once more.
  • Each disc receives a documentation of the processing steps, weights and other data as well as the responsible worker is seen.

Note: The manufacturer’s minimum specifications refer to the original brake disc so that it can be determined when the wear limit is reached. After processing refurbished brake discs are slightly thinner than original spare parts, the surface layer (wearing course) has, however, again the original measure, but with a higher density. This means that refurbished discs hold may take longer.

Before / after refurbishment

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worn PCCB rotor (Porsche 997 GT2)
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the same rotor after refurbishment

The production process for the refurbishment of ceramic brake disc

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The production process of a ceramic rotor

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The structure of DMC material

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