Vehicles with brake energy recuperation, i.e. BEV and HEV, make high demands on the corrosion resistance of brake rotors to avoid issues induced by corrosion. The reduction of rotor mass is of general relevance.

Ford and Fagor Ederlan have jointly developed a full aluminium brake rotor for passenger and SUV applications made from a hypereutectic aluminum alloy being corrosion resistant and fully benefiting from the aluminium's low weight. In opposite to known technologies there is no use of ceramic or similar reinforcements nor coating.

The technology, its integration into the brake system and its performance will be presented.

Marc Rettig, Supervisor Brake System Development, Ford Werke GmbH; Dr. Jaroslaw Grochowicz, Ford Werke GmbH; Klaus Käsgen, Ford Werke GmbH; Thomas Wilwers, Ford Werke GmbH; Ricardo Labrador, Fagor Ederlan; Nerea Egidazu, Fagor Ederlan; Idurre Gaztanaga, Fagor Ederlan; Dr. Clemens Verpoort, LSN ENgineering GmbH; Agusti Sin, ITT Friction Technologies