The refurbishing process in detail:

Step 1. 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.

ceramic-brake-disc-types

Step 2. After that any brake pad residue or contaminates is chemically steamed off.

Step 3. The rotors are machined until they are level.

Step 4. The napped are vacuum soaked in polymeric carbon – 2 – 3 times

vacuum-pressure impregnation system

Step 5. The next step is to pyrolyze the rotors at 1100°C.

Step 6. Now the discs are siliconized at 1500°C (only CCB rotors)

high temperature oven for pyrolysis and siliconizing (1500 degrees Celsius)

CCB: The friction layer (ca. 1mm thick) is now restored, and trough the pyrolysis it is chemically and physically bonded with the structure.

CCM: the structure of the disc is now strenghtened and repaired with new carbon fibres, the density of the core is increased throught infiltration of polymere material and trought the pyrolysis it is chemically and physically bonded with the structure

Step 7: Now follows the final resurfacing of the top layer by using a 2 ton sanding machine

The disc is completely reassembled and is weighed once more and precision-balanced.

The disc now has gained about up to 180g weight 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 (only CCM), 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

bremsscheibe-verschlissen
worn PCCB rotor (Porsche 997 GT2)
Pfeil_frei

bremsscheibe-erneuert
the same rotor after refurbishment

The production process for the refurbishment of ceramic brake disc

polymer-infiltration-pyrolysis

The production process of a ceramic rotor

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The structure of DMC material

dmc-struktur