Recent Advances and Environmental Considerations in Brake Disc Material Development

Abstract

Brake discs operate under extreme thermal, mechanical, and chemical stresses, requiring materials that balance durability, braking efficiency, cost, and environmental impact. This paper reviews recent developments in grey cast iron, titanium alloys, and ceramic–matrix composites, along with surface coatings, cryogenic treatments, and design-based thermal management. Improvements in material microstructure, surface engineering, and rotor geometry have improved wear resistance, heat dissipation, and overall braking stability. Growing environmental concerns are encouraging the adoption of cleaner, more sustainable materials and designs that reduce particulate emissions and prolong component lifespan.