Brake Rotor Material Selection

Materials Reviewed

Cast Iron
Steel
Metal-Matrix Composites

Selection Parameters

Wear Resistance
Weight
Thermal Capacity
Machinability
Availability
Cost Efficient

Cast Iron

High strength and durability to sustain torque loads from braking

Stable mechanical and frictional properties through range of expected service
temperatures.
High wear resistance through range of expected service temperatures.
High heat absorption capability to absorb braking energy
High thermal conductivity to transport frictional heat away from braking surfaces.
Minimal thermal expansion to minimize performance variability.
Low machinability
Costly.

Steel

Highly resistant to wear.

Doesnt shatter and resists heat very well.
High friction coefficient compared to cast iron.
Does not rust.
Excellent Machinability.
Easy Availability.
Light weighted.
High conductibility.
Cost Efficient.

Metal-Matrix Composites

High strength and stiffness.

High thermal conductivity.
Better wear resistance.
High strength to weight ratio hence better weight saving.
Low Machinability
Low Availability.

Final Selection Details

Our requirements:

High wear resistance.

Low weight.
High thermal capacity.
Easy availability.
Easy machinability.
Cost efficient.

MMCs are not cost efficient, not easy to manufacture and are not readily available.

Cast Iron is not readily available, not cost efficient and not at all easy to manufacture
however it has high strength, high wear resistance and high thermal conductivity which
is why most of the FSAE teams use it in their brake rotors.

Steel has lower strength, wear resistance and thermal capacity as compared to Cast Iron
but is has higher friction than Cast Iron and it does not rust easily. Also it is cost efficient,
readily available and is easy to manufacture.

So, we will be using Steel in manufacturing Brake Rotors as it is cost efficient(major factor), also
readily available and easy to manufacture.