Deeper Dive: Brake Engineering's Study On Critical Defects

Brake Engineering’s recent study has uncovered significant structural and mechanical defects in competitor brake calipers. The findings highlight serious safety concerns, including porosities and inferior material composition, which can compromise braking performance under normal driving conditions. This report aims to shed light on these defects and their potential implications for drivers’ safety.

Key Highlights:

29 defects detected in competitor brake calipers.
Porosities or voids were present in all tested units, weakening the structure.
Inhomogeneous microstructures and oxide inclusions were observed, leading to compromised performance.
One unit recorded a porosity size of 43.02mm.
Substandard materials used in castings, deviating from required specifications for hardness and tensile strength.
Testing focused on six critical areas of the calipers, all revealing concerning defects.

Brake Engineering‘s study identified 29 structural and mechanical defects across a range of competitor brake calipers. While these calipers may appear visually acceptable, closer examination revealed porosities (holes) and oxides within the material, as well as partly inhomogeneous microstructures. These defects significantly weaken the calipers, posing a potential threat to braking performance, particularly under heavy or emergency braking situations.

Brake Caliper Defects Spark Industry Debate

Porosity, a measure of void spaces within a material, was detected in all tested units. These large voids can lead to brake failure during intense braking, with one caliper displaying a porosity measuring 43.02mm. The study examined six critical areas of the calipers, including the machined radius and piston bore, with all sections showing defects.

Additionally, the caliper castings were found to be composed of lower-grade materials than specified, further compromising hardness and tensile strength. These substandard materials and construction issues raise serious concerns about the safety and reliability of these calipers in real-world driving conditions.

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