Brake Rotors

Brake Rotors

Racing improves the breed.  We’ve applied what we learned about racing brakes to road vehicles, and now offer brake rotors and pads to qualified fleets.  Use of cryogenically treated brakes can save hundreds of dollars per vehicle per year.

The United States Postal Service sponsored extensive testing to determine what the best brakes were for its fleet. Our Brake brand brakes were judged to be the best of all rotors tested.

The second place brake showed seven times the wear.

Fleets such as the US Postal Service have considerably reduced operating costs by using cryogenically treated brakes.

We’ve had treated and untreated brakes tested by Greening Testing Laboratories and Link Laboratories according to SAE 2707 JUL 2004 METHOD B, both independent testing labs that are well known for their work with brakes.  They found that brake rotors and pads lasted significantly longer after cryogenic treatment, with no significant change in braking effectiveness. In some cases treated brakes have lasted fo ur times longer than untreated ones.

Another test performed by Link Labs for us involved two rotors that were cycled according to SAE 2707 JUL 2004 METHOD B until the untreated rotor was worn beyond its service limit. The treated rotor was then put through the same cycles. It finished the test with 0.039″ less wear on the treated rotor

 

amout-of-wear

 

Why would you send your Vehicle out with inferior untreated rotors?

Brakes and the Environment

THIS IS NOT GREEN

rotors-rusted

The simple recycling of brake rotors is not the best strategy for the environment…

Cryo Processed Rotors Are.

Here is the energy budget life cycle of one treated rotor versus its equivalent untreated.

treated-untreated

*Does not include transportation and machining.

There are three strategies for dealing with used brake rotors.

 • Send them to the landfill

 • Send them to be recycled

 • Use cryogenically treated rotors, then send them to be recycled.

Obviously sending rotors to a landfill is not environmentally friendly.  Rotors are made of cast iron, which is easily recycled.  The mining and smelting of iron ore is energy intensive.   So it is environmentally friendly to send used brake rotors for recycling.  But recycling them results in the use of energy and can cause pollution.   There is a more environmentally friendly option.  Cryogenically treating rotors results in getting three or more times the use of the rotor before it has to be recycled.  Let’s take a look at the environmental results:

 To recycle a rotor, it is melted.  A common rotor for a full size car weighs about 24 pounds.

They just don’t melt a rotor, you melt a whole bunch of scrap metal, usually in a device called a copula.

 The energy use of a copula works out to about 800 kilo watt hours/metric tonne.

 If you do the math, this works out to about 9 Kilo Watt hours/24 pound rotor, which works out to about 31,000 BTU’s per rotor.

 But there’s more…….

 •  Gates, runners and risers in the mold require about 50% more metal than what is just in the brake rotor= BTU’s for the casting 46,500.

 •  Melting Metal:  a percentage is lost due to reacting with the atmosphere and creating dross or iron oxide.  This is about 7%.  So this represents another 3,255 BTU’s that are used to heat enough metal to replace the lost metal.

 •  To re-cast a brake rotor involves about 49,755 BTU’s of energy used, not counting what it takes to get it to the recycling plant nor the energy used to machine the resulting casting.

Let’s look at what happens when you cryogenically treat a rotor:

It takes about 8.2 liters of liquid nitrogen to process a rotor in our medium size machine.

Air Liquide tells us that to make that amount of liquid nitrogen would take about 2460 BTU.

The heating cycle in the machine also takes about 1000 BTU Electrical usage per rotor in the machine, for 3460 BTU.

The treated rotor will last about three times the life of the untreated rotor.

 NOTE:  The nitrogen used does not pollute the atmosphere.  It was taken from the atmosphere in the air separation process used to liquefy it, so it is just being released back from where it came.  The atmosphere is about 79% nitrogen to begin with.

Reduced Heavy Metal Pollution

Another advantage is that brake pads tend to last two times as long on treated rotor.  Brake pads contain copper which is worn off them and deposited along the road way where it makes its way into the sewer systems and into rivers.  Copper pollution is a major problem, especially along the coast lines where it does considerable damage to water life.  We can cut this pollution source considerably.