Steel, cast, metal cuttings and alloying additions – these are the ingredients of high-quality brake discs which can resist the tremendous forces that act upon them. Quartz sand, resin, hardener, and water-based slurries form the core of the brake disc, which will be completely covered with molten cast iron during the casting process.
A spectral analysis preceding every casting ensures the correct composition of the cast. Only after this analysis, the 1,300°C hot molten mass flows into the casting machine. The next step is the fully automatic further processing.
A measurement device checks the dimensional accuracy of the parts. With minimum production tolerances, latest systems drill, mill and polish the brake disc into the desired shape. Afterwards, it is painted fully automatically and dried by induction. Spectral analysis, 3D laser measurement, x-ray measuring procedures and repeated visual inspections ensure consistently high quality.
Brake discs are the central part of a braking system. Each year, the Bosch Group produces more than 20 million of them. Random brake-disc samples out of each production series are subject to further additional tests. Only if all quality tests and checks have been passed, the brake discs are delivered.