The upcoming Euro 7 standard focuses on pollutants created by non-exhaust components. Traditional cast iron brake discs have been identified as one of these components, producing a pollutant that is linked to a range of health complications.
To ensure compliance, automotive designers are looking towards alternative material solutions for brake discs like aluminium. With high-performance metal coating technology such as Plasma Electrolytic Oxidation, aluminium brake discs can not only guarantee compliance with Euro 7, but provide weight and design optimisations on top.
What is the Euro 7 standard?
The Euro 7 standard is an updated set of regulations from the European Commission that focuses on reducing the impact of automotive emissions. 7 is the first standard to include regulations on non-exhaust emissions and pollutants from specific components; this includes tailpipes, tyres and brakes. It comes into force in July 2025.
What are the challenges of traditional disc brakes?
Heavy - Traditional disc brakes are made of grey cast iron, which make them fairly heavy components. This is, of course, due to the thermal and abrasive resistance provided by the material. However, these disc brakes contribute significantly to overall vehicle weight, which leads to greater fuel consumption and emissions as a result.
Pollutants - Grey cast iron disc brakes produce harmful particulate matter PM10 as a non-exhaust emission (NEE). This dust has been studied closely, and has been linked to a range of acute health complications that pose a significant risk.
Rise of RBSs - Some electric vehicles (EVs) utilise a regenerative braking system (RBS) that acts as a reverse motor providing resistance against the motion of a vehicle. RBSs take a significant portion of braking power away from the pads, which can lead to corrosion for grey cast iron ones as they are colder and damper for longer. This can also lead to seizure following periods of inactivity.
The future of disc brake technology
Aluminium alternatives solve a number of challenges presented by traditional cast iron brake disks in light of Euro 7 standards. They are lighter, reduce total particulate emissions (PM10s) by nearly 80% and work in perfect harmony with RBSs. And thanks to advanced coating technology like Plasma Electrolytic Oxidation, aluminium disc brakes can have enhanced thermal and abrasion resistance to maximise their lifespan.
To find out more about the specifics surrounding cast iron and aluminium brake pads, read our latest research paper where we discuss the implications of PEO coated aluminium and how it can ensure compliance with Euro 7.
Keronite is now part of the CWST engineered coatings business.