Modern vehicles are generally equipped with braking systems composed of brake pads and rotors. Understanding and defining their inherent limitations is critical for developing innovative technologies and formulating products to enhance existing characteristics.

The brake pads are crafted from a friction material designed to produce the required stopping force when pressed against the rotors. Upon pressing the brake pedal, brake calipers compel the brake pads to grip the rotors tightly, initiating friction. This friction, in turn, transforms the vehicle's kinetic energy into heat, resulting in the vehicle's deceleration or complete stop. The pressure applied during braking plays a pivotal role in the performance of the braking system, significantly influencing its properties. As the pressure intensifies, the force exerted by the brake pads on the disc surface increases. This heightened pressure augments the friction between the brake pad and the disc surface, resulting in increased wear on the braking system.

Furthermore, applying elevated pressure contributes to a rise in the temperature of the disc surface. Simultaneously, the organic constituents within the composition of the friction material, responsible for regulating friction and wear characteristics, undergo thermal degradation. This degradation substantially influences friction performance and leads to a decline in mechanical strength. Effectively managing and dissipating this heat is crucial to prevent brake fading, a condition where brakes overheat and lose effectiveness in slowing down the vehicle.

Moreover, GCI brake discs are prone to corrosion, which becomes a more significant concern when the brakes remain stationary or not used for extended periods in humid environments. The corrosion of brake discs can lead to a decrease in braking efficiency, with the added risk of corrosion adhesion, especially between surfaces into contact, causing severe damage and doubling the number and the mass of the non-exhaust particulate emissions.

With the increasing demand to meet the Euro7 particulate emission requirements, the brake system's performance has become a critical consideration for car manufacturers and passengers. The braking system is required to endure high temperatures and pressures and resist excessive rust buildup while maintaining a sufficient coefficient of friction. Additionally, there is a need to extend their lifespan, preserving their original performance with minimal wear.

The present study aims to show the effectiveness of the Nitrex ferritic nitrocarburizing FNC-Smart ONC® technology with a controlled compound layer and a non-toxic, self-healing oxide protective film. It provides high corrosion resistance to the GCI rotors while enhancing wear resistance. Results from dyno testing, conducted in compliance with SAE 277B standards, reveal that the compound layer remains intact, the mechanical properties are thus maintained, and there is no delamination or cracking in the coating, indicating an extended lifespan of the brake disc. The FNC-Smart ONC® discs exhibited pad material accumulation, serving as a protective interface between the pads and the disc and effectively preventing their erosion. This innovative technology offers the added benefit of maintaining braking performance without increasing the vehicle's braking distance. Ongoing investigations involve multiple consecutive SAE J277B test cycles to further explore this prolonged durability.

Brake discs are subject to various types of punishments, ranging from wear to enduring harsh environmental conditions, releasing non-exhaust emissions that contribute to traffic pollution and make it difficult to comply with stricter environmental standards. Therefore, with the upcoming Euro 7 regulations, the automotive industry will need to find cost-effective solutions to reduce emissions from the braking systems of both, internal combustion engine vehicles (ICEVs) and electric vehicles (EVs). EVs and ICEVs differ significantly in their braking systems. Conventional vehicles primarily use friction braking, in which kinetic energy is converted into heat by brake discs and pads. In contrast, EVs use regenerative braking to convert kinetic energy into electrical energy, which is then used to charge the batteries. Until the batteries are fully charged, EVs rely almost exclusively on recuperation up to speeds of about 20 km/h and use friction braking only to bring the vehicle to a complete stop. This reduces the frequency of friction brake use. Since cast iron (GCI) rotors are susceptible to corrosion, they will rust if not used. In GCI rotors that have not been treated to resist corrosion, the corrosion goes inside the rotor, damaging the surface and penetrating deeper. When braking, the rust is removed and with it some of the surrounding material. This results in a higher mass loss compared to a non-corroded GCI rotor and effects such as pedal pulsation. Thus, the reduction in particulate mass (PM) comes mainly from reduced brake use, and the brakes can survive these conditions with less corrosion without being de-rusted by brake use. This problem can be effectively addressed by using a ferritic nitrocarburizing (FNC) in conjunction with specific oxidation, resulting in rotors that experience less corrosion overall and only on the surface. To further improve the corrosion resistance of FNC rotors, Nitrex R&D has developed an advanced nitrocarburizing technology using a dual heat treatment process that combines nitrocarburizing with in-process intelligent post-oxidation. The result of this new approach has led to a remarkable increase in corrosion resistance. The treated rotors can be exposed to salt spray for up to 120 hours without corrosion. This is a significant improvement over the FNC-treated rotors, which can only be exposed to salt spray for less than 20 hours.