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Automotive Pet Peeves 2: Reader Feedback Is Overwhelming

How many auto repair pet peeves are out there? Well, enough of them that one article wouldn’t hold them all. I’ve received so many emails, texts and phone calls about my article in the February issue that I thought: why not put everyone’s pet peeve...

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Air Filter Show & Tell: Seeing Is Believing

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Searching For 'Black Holes': Job Totals Reveal Missed Selling Opportunities

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KIA: Brake Light On, Tachometer And Speedometer Inoperative

Applicable Models: 2001 Kia Optima LX, 2.4L Complaint The customer states the red brake light is illuminated on the instrument cluster. The ­customer also states the tachometer and speedometer intermittently stop working. Cause Confirmed the customer’s...

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Mazda: Fuel System Servicing Precaution

Applicable Models: 2004-’07 Mazda3 2005-’07 Mazda6 2006-’07 MX-5 vehicles During service/removal of fuel system parts on the above vehicles, the memory of the malfunctions and the long-term fuel trim need to be cleared by either removing the...

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Top 5 Tools: Daniel Sjobeck, Roseville Auto Repair

Daniel Sjobeck, tech Roseville Auto Repair Roseville, MN A good toolbox. You can have the best of everything, but it’s no use if you cannot find it. Power Probe – One of the greatest ­inventions EVER. Snap-on Digital Torque Wrenches Snap-on...

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Mitchell 1 ProDemand Consolidates Vintage Repair and Estimating Information

Mitchell 1 has updated its ProDemand repair, diagnostic and maintenance software by consolidating vintage repair and estimating information into the application to deliver full year, make and model coverage from 1974 to the present year. This latest enhancement...

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Pulling Codes: Multiple Misfire Personalities

A Story of Codes P0302, 04, 06, 08 & 03   This month’s diagnostic journey begins with a 2008 Land Rover Discovery that is taken in to a local testing facility for an emission test and fails due to a series of misfire codes. Misfire...

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Diagnostic Dilemma: The Case of the Missing Code

When doing mobile diagnostic work, no-code stalling complaints are a major part of your agenda. In most cases, the client shop is simply too busy to duplicate the failure or, in some cases, a long test drive will yield nothing in the way of useful...

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Secondary Ignition: The Art of Spark

What is a coil? From the beginning of the internal combustion engine, several different ignition systems have been used to create a high-energy spark. The most popular system, and the one that’s in use today, is a step-up coil. A coil is nothing...

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Diagnosing Catalytic Converter Failure Symptoms

Although construction can vary according to engine application, the common three-way catalytic converter contains a reduction and oxidation stage. To create maximum surface area, each stage is generally a ­ceramic or stainless steel honeycomb substrate...

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Home Brakes High Performance Brakes: Carbon Ceramic Rotors

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While it may seem like these systems are untouchable like some super models, this expensive option on some high performance vehicles could be the brake of the future if they manage to bring the costs down.

Ceramic composite rotors are extremely durable. In fact, manufacturers claim that they’ll never need replacement — at least with "normal" driving. They’re also resistant to the kind of distortions and wear that leads to pedal pulsation — merely an annoyance in the “real world,” but a noticeable performance issue on the track.
Manufacturing
The brake discs are formed from a specially treated carbon-fiber compound that is silicated in a high-vacuum process at higher temperatures then any stop could produce. Not only are the resulting discs much harder than standard discs, they are more resistant to heat. The process used to produce the discs for CCB is complex and time-consuming  and costly when compared to cast iron.

The carbon fibers are blended with a resin of carbon and silicon. The mixture is pressed into a mold to create the basic disc shape, including its internal cooling vents. Using heat up to 3,000º F, the resin is converted to silicon carbide, a material nearly as hard as diamond. This is the “ceramic” in “carbon ceramic.” If you tried to machine these rotors, you would need diamond tipped bits in your brake lathe.

The low thermal expansion of the brake discs prevents deformation under heavy braking. Furthermore, the ceramic brake discs are totally resistant to corrosion and offer more favorable noise-damping properties.
 
Advantages
Because of their exceptional performance in extreme conditions, ceramic composite brakes were developed for use in high-level motorsports competition. Porsche was the first automaker to apply them for road use, with Porsche Ceramic Composite Brakes included as standard equipment in the Porsche GT2 and Carrera GT and as an option in most other models.

Ceramic composite brake discs provide a 50-percent weight savings compared to conventional metal discs. This reduces unsprung weight, enhances shock absorber response and vehicle handling, and also improves fuel efficiency and contributes to reduced emissions.

Ceramic composite brake discs have an extremely hard surface that provides consistent frictional values throughout the deceleration process, even in braking from extremely high speeds and at high operating temperatures, such as those generated from repeated braking. But the system also provides benefits in low-speed situations.  In the event of an emergency stop, the technology does not require heavy pedal forces or outside technological boosting assistance to achieve maximum and immediate stopping force.

With cross-drilled discs and pads that are resistant to water absorption, the ceramic composite brakes provide superior response in wet conditions as well as dry. Because of their hard surface and immunity to salt corrosion, Porsche Ceramic Composite Brakes have an extremely long operating life.
Service Life
Porsche Ceramic Composite Brakes have been on the market for almost 10 years. There have been no recalls or lawsuits. There have been some complaints on low speed noise, but Porsche’s advice is to warm them up.

The only real complaints with the ceramic disc have come from weekend racers who have experienced cracked discs due to extreme abuse. Porsche’s advice to these drives is to check for cracks before they head out to the track. With the replacement costs of four disc and pads costing more than $20,000, many are switching to cast iron rotors and semi-metallic pads.  
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Andrew Markel

Andrew Markel is an ASE Certified Technician and former service writer, and he brings this practical knowledge to the Brake & Front End team as editor.

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