Achieving Euro 7 Compliance: Cost-Effective Brake Wear Particle Emissions and Performance with FNC-Smart ONC® GCI Rotors

Over the past few years, NITREX has developed an advanced ferritic nitrocarburizing process combined with a specialized post-oxidation treatment known as FNC + Smart ONC®. This innovative approach allows the use of grey cast iron brake rotors in their original form, significantly reducing PM 10 emissions to levels below the Euro 7 limits for most vehicles equipped with at least some recuperative braking capabilities, all without compromising performance. We have rigorously tested these rotors according to several industry standards, including SAE J2707B (Block Wear Test including Highway), GRPE-81-12 Emission Test (Full WLTP Brake Cycle 6 Times), and SAE J2522 (AK-Master Performance). These tests were designed to compare the behavior of treated rotors against standard untreated rotors, as well as to evaluate performance with different lining materials. Additionally, our process addresses the issue of corrosion, which is particularly relevant for brake rotors that experience less use in vehicles with recuperative braking systems. This reduction in corrosion could potentially eliminate the need for the conventional practice of painting rotors. To validate this, we conducted tests in accordance with SAE J2334 (Cyclic Corrosion, 36 cycles). The presentation will provide a comprehensive overview of the applied process and then delve into the findings from the standardized tests mentioned above. In conclusion, we will summarize and evaluate how this technology can meet the emission requirements for nearly all new vehicles and even achieve a reduction in brake emissions by at least 50 percent for existing vehicles without recuperative braking systems. All of this can be accomplished at a very moderate cost compared to other solutions.