Weight-reduction efforts in the automotive industry have increased significantly in recent years, in an effort to reduce fuel consumption and CO2 emissions. As a result, manufacturers are moving to aluminium based material solutions to help reduce vehicle weight, provide for better fuel economy and improve overall sustainability credentials. Adopting aluminium brake discs would reduce weight by up to 15kg for an mid sized ICE car and deliver considerable fuel savings across the life of a vehicle (~200litres). Furthermore, reducing rotational inertia through lighter discs, leads to better handling performance, improved acceleration, and shorter braking distances. Of potentially greater importance, particulates from brakes are now the largest source of emissions from cars. Nanoparticles of copper and iron oxide from brake discs and pads are of particular health and environmental concern. Hard-wearing ceramic-coated aluminium discs would eliminate iron oxide particulates from the disc and also could be used in conjunction with copper-free brake pads.
Lightweight high performance carbon fibre reinforced ceramic (CFRC) disc brakes are available, however their high cost makes them an unviable option outside of the high performance car and motor racing markets. Without a cost-effective lightweight alternative to heavy cast iron brakes - which have seen relatively little innovation since their introduction over 50 years ago - fuel efficiency, range and drive handling needs of the customer will continue to be significantly compromised.
Keronite Limited has developed RELIABLE, a wear resistant lightweight aluminium brake disc for use across the automotive sector that addresses the current limitations of aluminium alloys and ceramic coatings. Objectives of the overall innovation project are to refine, scale-up and bring to market readiness our novel RELIABLE brake disc. RELIABLE will be a “market first”, fully satisfying the need for a cost-effective lightweight brake disk and deliver a wide-range of end-user benefits.
The Phase 1 Feasibility Study is an important step in achieving our overall Innovation Project objectives. The specific objectives of the Phase 1 study were
FS1 Risk assessment: To identify, assess and mitigate against any project risks that could impinge upon our ability to fully develop and commercialise our RELIABLE technology. Risk areas that will be assessed include: technical, legislative/regulatory, financial, commercial and political factors.
FS2 User Engagement: To undertake further engagement in order to validate the market needs & design specifications that we have already established.
FS3 Innovation strategy development: To develop our innovation strategy, part of which includes future work plans, potential collaborative partners, roadmap of future enhancements and novel developments etc.
FS4 Detailed Market Study: To validate our understanding of the market size, dynamics, and design considerations. We will establish the most appropriate routes to market such as acting as a “Tier 2” organisation, supplying to “Tier 1” braking system providers.
FS5 IP Management: Whilst we already have patents in place for both our process technology and coating material, we will seek advice on enhanced protection specifically for the automotive sector.
FS6 Business plan: To elaborate our initial business plan, incorporating the data gained from the feasibility study.
