Mining Truck Brakes- Case Study

The Problem

A major mining company in Australia tested cryogenically treated brake rotors vs. untreated rotors with dramatic results. They were experiencing an issue with the excessive wear and cracking on the service brake rotors and brake pads on the 730E Komatsu trucks in their fleet and were trying to find a cost-effective solution.

The Experiment

The brakes on their 2000 horsepower trucks have a gross weight of 715,000 pounds to stop from speeds up to 35 mph. Each side on the front has a 46-inch diameter rotor operated by three calipers. Each side on the rear has two 25 inch rotors driven at armature speed. Each rear rotor has one caliper.

In an attempt to explore the problem, treated Komatsu brake rotors were installed to the left-hand side of one of the trucks in service. The right-hand side was fitted with standard untreated Komatsu rotors to act as a control.


The Results

After one month the brakes were inspected and it was found that the treated rotor had no cracks and the untreated one had severe cracking to the braking surface. At this time, the pads on the treated rotor had worn 1.5 mm as opposed to 7 mm on the pads on the untreated rotor. The untreated rotors were replaced.

The next inspection recorded was at 5 months. At this stage, the treated rotor was still on and had developed some cracking but these were quite minor in size when compared to the untreated side. The right-hand side had already had its second rotor fitted which was now cracked far more severely than the original.

Untreated Rotor After 2 Months of Use 


Treated Rotor After 5 Months of Use


The Company’s Report

“It is obvious to date that the treated rotor will outlast at least 3 conventional rotors and in fact will be monitored weekly just to see how far it will go before it needs to be discarded. The deep and open cracking of the conventional rotor in such a short time will affect the pad wear quite considerably given the speed at which these rotors rotate in service which in this instance is 27:1 compared to the tire rotation.”


Contact Controlled Thermal Processing Today

If you run a business that requires operating vehicle fleets or construction equipment, you’re always looking for a way to improve your bottom line by reducing wasted resources. With deep cryogenic processing of brake rotors and crown wheels, you can dramatically reduce your maintenance and replacement costs. To get an estimate for treating your automotive parts with cryogenic processing, contact the specialists at CTP online or by phone at +1 (818)-445-3030.