Brake disc

Brake disc

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The brake disc is the component of a disc brake against which the brake pads are applied. The material is typically grey iron, a form of cast iron. The design of the disc varies somewhat. Some are simply solid, but others are hollowed out with fins or vanes joining together the disc's two contact surfaces (usually included as part of a casting process). The weight and power of the vehicle determines the need for ventilated discs.  The "ventilated" disc design helps to dissipate the generated heat and is commonly used on the more-heavily-loaded front discs.

Beginning in the 1960s on racing cars, it is now common for high-performance cars, motorcycles and even bicycles, to have brakes with drilled holes or slots. This "cross-drilling" is done for a number of reasons: heat dissipation, surface-water dispersal, brake squeal elimination, mass reduction, or marketing cosmetics. An alleged disadvantage of cross drilling for racing or other severe conditions is that the holes might become a source of stress cracks.

Discs may also be slotted, where shallow channels are machined into the disc to aid in removing dust and gas. Slotting is the preferred method in most racing environments to remove gas and water and to deglaze brake pads. Some discs are both drilled and slotted. Slotted discs are generally not used on standard vehicles because they quickly wear down brake pads; however, this removal of material is beneficial to race vehicles since it keeps the pads soft and avoids vitrification of their surfaces.

As a way of avoiding thermal stress, cracking and warping, the disc is sometimes mounted in a half loose way to the hub with coarse splines. This allows the disc to expand in a controlled symmetrical way and with less unwanted heat transfer to the hub.

On the road, drilled or slotted discs still have a positive effect in wet conditions because the holes or slots prevent a film of water building up between the disc and the pads. Cross-drilled discs may eventually crack at the holes due to metal fatigue. Cross-drilled brakes that are manufactured poorly or subjected to high stresses will crack much sooner and more severely.

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