For commercial vehicles (CV), where heavy loads and extended service life are common demands, the integrity of the braking system is paramount for both safety and cost-efficiency. While original equipment manufacturers (OEMs) understand the benefits of precisely matching the brake pads and discs for optimum brake performance, this has not yet become established in the independent aftermarket.
Textar is on a mission to educate on the importance of perfectly pairing the pads and discs after its R&D experts found alarming new insights into disc cracking when testing several competitor disc products.
The crucial role of brakes for CVs
Brakes are one of the most vital safety components on any vehicle, but their importance is magnified on commercial vehicles due to the size, weight, and nature of their operations.
Commercial vehicles, such as trucks and buses, are significantly heavier than passenger cars. This increased weight means they require more force to stop. Effective brakes ensure these vehicles can stop within a safe distance, preventing accidents. Without reliable brakes, the stopping distance increases dramatically, posing a risk to the driver, passengers, and other road users.
Whilst brake failure is rare, it can still occur, especially if defective or countefeit parts are used. Research has shown that 30% of accidents in trucks are due to a faulty part or deficient brakes. However, the R&D experts at Textar recently found that disc cracking can also occur if the brake pads and discs are not a perfect match.
What does disc cracking mean?
Disc cracking typically occurs when the brake disc is subjected to repeated stress and high temperatures, causing microscopic cracks that deepen over time. Cracks in the brake disc act like a plane on the brake pad. They remove the friction material from the brake pad, leading to uneven wear, and, in worst-case scenarios, could even cause unexpected brake failure. Such failures could have dire consequences in the event of an emergency stop, especially in commercial vehicles due to the intense braking energy required to halt their substantial weight.
The impact of unmatched brake pads and discs
Textar products undergo rigorous testing and quality checks throughout the development of the brake pads and during the testing phases before they are released to the market. R&D experts also carefully evaluate the behaviour of the brake disc early in the material development process to ensure it works in harmony with the pad. But when replacing the pads and discs in the aftermarket, the perfect pairing is not always chosen, possibly due to budget and time constraints.
Textar’s R&D experts wanted to check the quality and durability of mismatched parts when this does happen. The results were disturbing.
In addition to testing Textar’s pads and discs, R&D experts conducted tests on 33 competitor parts. All products were subjected to more than 250 brake applications during the cycle of the investigations. As trucks on general running will reach temperatures of up to 300°C, rising to approximately 750°C on extreme downhill braking, the tests replicated an average of over 450°C with a typical pressure of 3 Bar during the brake applications. The tests ran for over 50 hours. Several competitor parts failed halfway through the test and only reached 120 brake applications, which is very concerning when brakes are a safety critical item for any vehicle on our roads. In real life conditions, this would lead to brake failure.
The results showed that if the brake pad and disc did not match, and therefore were not compatible to the best possible extent, the first hairline cracks in the brake disc would start to form after just a few hard braking applications, becoming deeper with each subsequent braking application. Incompatible pads and discs were shown to not only influence the safety of the vehicle but also increase wear on the brake pads, meaning the brake pads and discs needed to be replaced earlier than otherwise necessary.
Recommendations for technicians and fleet operators
To prevent disc cracking and ensure the longevity of brake components, Textar advises technicians and fleet operators to:
- Use parts that are designed to match: Always choose brake pads and discs from reputable brands that are designed to work together. This compatibility minimises the risk of disc cracking and uneven pad wear.
- Perform regular checks for cracking and wear: Frequent inspection of the brake discs for signs of cracking and other wear issues can catch problems early, preventing unexpected failures on the road.
- Follow manufacturer guidelines for replacement: Replacing components according to OEM specifications – or sooner, if cracks or wear are detected – helps maintain optimal braking performance.
By taking these proactive steps, technicians and fleet operators can ensure greater braking reliability, reduce maintenance costs, and safeguard the safety of commercial vehicles on the road.
Textar’s commitment to quality
While budget constraints may tempt some operators to choose cheaper, potentially incompatible brake components, this cost-cutting approach can lead to increased expenses in the long run. The early failure of mismatched pads and discs means that replacement intervals are shortened, causing additional parts costs, labour expenses, and vehicle downtime.
Textar prioritises extensive research and development, including rigorous testing of brake components under real-world conditions, to ensure durability and performance. Through its commitment to quality, Textar strives to bring OEM-level performance to the aftermarket sector. With each brake pad going through up to three years of development and testing, customers can trust in the reliability of Textar products.
For technicians looking to source high-quality, compatible brake components, Textar provides a comprehensive product catalogue through its Brakebook online platform and app, offering convenient access to the latest in brake technology.
In the world of commercial vehicles, brake system integrity cannot be compromised. Properly matched brake pads and discs not only prevent dangerous disc cracking but also ensure that vehicles are safe, reliable, and cost-efficient on the road.
Find the right Textar parts quickly using the online Brakebook catalogue at: https://textar.com/en/brakebook or on the go via the app.