In the long iteration of automotive braking technology, the emergence of carbon ceramic brake discs (C/SiC) is undoubtedly a disruptive breakthrough. As a composite new material product with carbon fiber as reinforcement and silicon carbide ceramic as matrix, it perfectly combines the high strength and toughness of carbon fiber with the high temperature and wear resistance of silicon carbide ceramic, breaking the performance bottleneck of traditional braking materials under extreme working conditions. It has gradually penetrated from the aerospace field to high-end automobiles, rail transit and other scenarios, and has become one of the core symbols for measuring the high performance of equipment.
1. Core characteristics: Breaking through the performance boundaries of traditional materials

The excellent performance of carbon ceramic brake discs stems from its unique material combination and microstructure. Compared with mainstream gray cast iron brake discs, it presents all-round advantages, but also has certain technical limitations.

(1) Core advantages demonstrate technological leadership

- Extremely lightweight: The density is only 1/4 to 1/3 of cast iron. A pair of 380mm carbon ceramic brake discs weighs about 12kg, while similar cast iron discs weigh 32kg, a weight reduction of 50%. This reduction in unsprung mass has a significant effect. Every 1kg weight loss below the suspension system is equivalent to a 5kg weight loss in the car body, which can increase the driving range of new energy vehicles by 25km and reduce the fuel consumption of fuel vehicles by 0.3-0.6L per 100 kilometers. It also optimizes wheel bounce and grip, and improves vehicle controllability.

- Super high temperature resistance and thermal decay resistance: It can withstand high temperatures above 1650°C, far exceeding the critical temperature of 500°C where pearlite decomposition and thermal fatigue cracks occur in cast iron plates. In continuous high-intensity braking scenarios, its friction coefficient can be stably maintained in the range of 0.35-0.45. In high-temperature environments above 200°C, the friction coefficient actually increases slightly, completely solving the pain point of high-temperature braking failure of traditional materials.

- Ultra-long service life and corrosion resistance: The service life can reach 500,000-1 million kilometers, which is 5-10 times that of cast iron plates. It also has excellent rust resistance, so there is no need to worry about oxidation loss in humid environments. Brembo's carbon-ceramic brake discs also rely on this property to maintain stable performance in both dry and wet conditions.

- Fast braking response: The maximum braking force can be output in the initial stage of braking, and millisecond-level response of brake-by-wire can be achieved without the need for additional auxiliary systems, providing accurate braking execution guarantee for intelligent driving. Compared with traditional braking systems, the braking distance can be shortened by more than 2 meters.

(2) Existing technology and cost limitations

Despite its excellent performance, carbon ceramic brake discs still have obstacles to popularization: first, the manufacturing cost is high, and the price of a single set was once as high as 340,000 yuan. Although large-scale production optimization is expected to drop to the range of 18,000-25,000 yuan in 2025, it is still far more than that of cast iron discs; second, the preparation time The long-term fiber process takes 2 months, and the high-temperature processing process accounts for more than 50% of the energy consumption; third, the use scenarios are limited. When the track temperature exceeds 600°C, an efficient heat dissipation system is required. Otherwise, the carbon fiber is easily oxidized and damaged, and special brake pads are required to match, which consumes relatively faster.

2. Technology evolution and preparation technology: from aviation-grade technology to large-scale civilian use

(1) Technology development context

The origin of carbon ceramic braking technology can be traced back to the 1970s. It was initially used in aerospace vehicle braking systems to cope with the extreme loads of high-speed takeoff and landing with its high temperature resistance. In the 1980s, it gradually moved into the racing field and became a core component to ensure braking safety in top events. In 2002, Brembo Group took the lead in mass-producing carbon ceramic brake discs for automobiles, and installed them on Ferrari Enzo models, pioneering the application of high-performance civilian brake discs. In 2004, this type of braking equipment won the Compasso d'Or award from the Italian ADI Industrial Design Association, marking dual recognition of its technology and design.

(2) Mainstream preparation processes and classifications

According to the state of carbon fiber, carbon ceramic brake discs are mainly divided into short fiber discs and long fiber discs. The difference in process routes directly determines product performance and cost:

1. Short fiber disk: It adopts a simplified process of mixing, molding, carbonization, ceramicization, and deduplication assembly. The preparation cycle is only one month, with high raw material utilization and low overall cost. The representative product is Brembo CCM disk, but its mechanical properties are limited, its strength and toughness are poor, and it is prone to problems such as falling pieces and fractures. It is suitable for high-end civilian vehicles with moderate performance requirements.

2. Long fiber disc: It is made through multiple processes such as carbon fiber preform molding, resin curing, high-temperature carbonization, SiC ceramicization, mechanical processing, and balance verification. The core relies on the combined technology of CVI (Chemical Vapor Phase Infiltration) and LPI (Liquid Phase Infiltration). First, CVI is used to improve the structural uniformity, and then LPI is used to supplement the density. The product has excellent strength, toughness and wear resistance. Brembo CCB high-end models and domestic P-C/C-SiC discs all fall into this category. However, the preparation cycle is as long as 2 months, the material loss rate is high, and the cost is significantly higher than that of short fiber discs. They are mainly used in racing, supercars and aerospace fields.

3. Application scenarios: from high-end niche to multi-field penetration

The application scenarios of carbon ceramic brake discs are gradually expanding from the initial high-end niche fields to civilian fields such as new energy vehicles and rail transit, forming a diversified demand pattern.

(1) Automobile field: Supercars lead the way, new energy models become new growth points

Currently, the Brembo SGL joint venture is a global leader, and its products have been assembled in top models of ultra-luxury brands such as Ferrari, Lamborghini, Porsche, and Bentley. The Ferrari 488 GTB is equipped with a monocoque brake caliper and carbon ceramic disc that can withstand high-load piston pressure; the Lamborghini Aventador's 6-piston front caliper and carbon ceramic disc combination combine performance and appearance design; the Pagani Huayra relies on this braking system to maintain a stable friction coefficient under the extreme conditions of the Nürburgring track.

The rise of new energy vehicles has brought new opportunities for carbon ceramic brake discs. Due to the rapid speed of electric vehicles, their heavy weight, and stringent requirements for lightweight and braking safety, OEMs such as BYD and NIO have begun to apply them in batches, and the penetration rate of new energy vehicles worth more than 300,000 yuan has exceeded 15%. It is expected that by 2028, its standard equipment rate in new energy luxury models will reach 45%.

(2) Aerospace and rail transportation: performance guarantee of high-end equipment

In the aviation field, the C919 large aircraft demonstrator has completed more than 200 carbon ceramic brake disc take-off and landing tests, reducing weight by 120kg per flight and reducing fuel consumption by 1.2%-1.5%, becoming a key component for lightweighting civil aircraft. In the field of rail transportation, the Fuxing intelligent EMU has carried out loading tests, with the braking distance shortened by 18% and the service life extended by 3-5 times. CRRC plans to realize the commercial application of 350km/h high-speed rail by 2025. The braking system of a single train set is worth 6-8 million yuan.

(3) Emerging fields: expanded application of industrial scenarios

In the field of wind power, the use of carbon ceramic brakes for offshore wind turbines above 5MW can reduce weight by 1.2 tons and improve power generation efficiency by 0.8%-1.2%. Goldwind Technology's proportion of related orders in 2024 has exceeded 15%. In addition, this material is gradually being used in industrial machinery, special vehicles and other scenarios that have strict requirements on braking performance and durability.

4. Industry status quo and future trends: localization is accelerating and cost optimization is key

(1) Market structure: Foreign capital dominates, local companies break through

The global market has long been monopolized by international manufacturers such as Brembo and Surface Transforms, which have dominated the high-end market with their technological accumulation, patent layout and brand advantages. The Chinese market is accelerating to catch up. The localization rate has increased to 38% in 2023, and is expected to exceed 60% in 2030. Domestic companies have formed four types of breakthrough paths: professional carbon-based material manufacturers (Jinbo Co., Ltd., Tianyi Shangjia) reuse thermal field technology; aviation technology transformation companies (Beimo Hi-Tech, Boyun New Materials) transplant military technology; traditional brake manufacturers (Jin Qilin) ​​enter through cooperative research and development; diversified materials groups (Chujiang New Materials) rely on the advantages of prefabricated technology.

The market size is growing rapidly. It is expected that the average annual compound growth rate of China's carbon ceramic brake disc industry will exceed 30% from 2023 to 2030, and the market size will increase from 1.25 billion yuan to more than 8 billion yuan. The commercial vehicle field is expected to form an incremental market of 3 billion yuan.

(2) Development trend: two-wheel drive of technological upgrading and cost decline

- Technology iteration continues to make breakthroughs: in terms of materials, ZrB₂-SiC gradient coating technology increases the anti-oxidation temperature to 1600°C; in terms of structural design, 3D weaving + directional flow channel design increases heat capacity by 25%, and laser drilling technology improves heat dissipation efficiency by 40%; intelligent manufacturing promotes full-process automation, and Chujiang New Materials’ intelligent production line increases the annual production capacity of a single line from 5,000 pieces to 30,000 pieces, with a consistency of 99.3%.

- The cost optimization path is clear: the upstream carbon fiber localization rate has increased to 80.46%, and the price of T300 grade has dropped from 2 million yuan/ton in 2015 to 800,000-1 million yuan/ton; the midstream has reduced energy consumption by 40% through process optimization (such as fast CVI furnace); large-scale production has caused the price of a single set to continue to decline, laying the foundation for popularization.

- Policy and capital support: "Energy Saving and New Energy Vehicle Technology Roadmap 2.0" lists carbon ceramic braking systems as a key direction, "Made in China 2025" promotes innovation throughout the industry chain, special subsidies will reach 420 million yuan in 2023, cumulative financing in the capital market exceeds 5 billion yuan, and R&D investment intensity generally exceeds 8%.

- The formation of a circular economy model: Central South University's microwave pyrolysis technology achieves a carbon fiber recovery rate of 95%, a silicon carbide recovery rate of 85%, and a recycled material performance retention rate of over 90%, further reducing the entire life cycle cost.

5. Summary

Carbon ceramic brake discs are reshaping the competitive landscape in the field of high-performance braking with their core advantages of lightweight, high temperature resistance, and long life. From the extreme working conditions of aerospace to the daily driving control of new energy vehicles, from foreign monopoly to local breakthrough, the industry is in a golden development period of technological upgrading and market expansion. As costs continue to decline, technology continues to mature and application scenarios expand, carbon ceramic brake discs will gradually move from high-end niche products to large-scale popularization, providing core support for the lightweight and intelligent transformation of the automotive industry and high-end equipment upgrades, opening a new era of braking technology.