This article presents a structural-comparative analysis of the applicability of various materials for pressure brake discs in racing cars under extreme thermal and mechanical loads. The study is conducted within an interdisciplinary framework combining materials science, thermal modeling, and engineering mechanics. Special attention is given to microstructural and fractographic analysis of steels (AISI 1020, AISI 4140, SS420), carbon-ceramic composites (C/C, SiC), and their combinations in hybrid layered configurations. Differences in material behavior are identified based on key criteria such as thermal expansion, oxidation resistance, microcrack formation, and residual deformation. Based on numerical modeling in ANSYS and analysis of a real track profile (“Michigan 2019” circuit), a correlation between thermocyclic degradation and track configuration, rotor geometry, and ventilation features is established. Comparative analysis shows that C/C and SiC discs provide more uniform wear and stable friction coefficients at temperatures above 1000 °C, while steels exhibit limited suitability under intensive braking conditions. The potential of biomimetic textures and fluoropolymer (PTFE) coatings to enhance heat dissipation efficiency is substantiated. The article will be of interest to specialists in motorsport engineering, materials science, thermomechanics, and brake system design, as well as developers of composite structures operating under high thermal loads.

pressure disc, motorsport, carbon-ceramic, thermal resistance

Galvanini, G., Gobbi, M., Mastinu, G., Cantoni, C., & Passoni, R. (2025). Thermoelastic modeling of high-performance carbon–carbon (C/C) brakes. Thermal Science and Engineering Progress, 63, 103664. https://doi.org/10.1016/j.tsep.2025.103664

Li, D., Sun, D., Xi, H., & Dai, J. (2024). Review on the mechanism of failure mode based on mechanical performance analysis of brake disc. Advances in Mechanical Engineering, 16(12). https://doi.org/10.1177/16878132241298368

Hasanlu, M., Shirvani, F., & Mahdian, S. (2025). Experimental thermal fatigue crack on brake disc of heavy vehicle. Material Science, Engineering and Applications, 5(1), 1–19. https://doi.org/10.21595/msea.2025.24729

Balu, L. C., & Rajendra, R. (2023). Analysis of disc brake with composite materials. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2023.07.288

Ötkür, M., Fasahi, I., Waseem, T., Zattam, O., & others. (2024, August). Disc brake rotor thermal analysis for a Formula SAE race car. In The 10th World Congress on Mechanical, Chemical, and Material Engineering. https://doi.org/10.11159/icmie24.151

Choudhary, A., Gujare, A., Dayane, S., & Dhatrak, P. (2023). Evaluation of thermo-mechanical properties of three different materials to improve the strength of disc brake rotor. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2023.02.028

Park, S., Lee, K., Kim, S., & Kim, J. (2022). Brake-disc holes and slit shape design to improve heat dissipation performance and structural stability. Applied Sciences, 12(3), 1171. https://doi.org/10.3390/app12031171

Li, W., Yang, X., Wang, S., Xiao, J., & Hou, Q. (2021). Research and prospect of ceramics for automotive disc-brakes. Ceramics International, 47(8), 10442–10463. https://doi.org/10.1016/j.ceramint.2020.12.206

Liang, H., Shan, C., Wang, X., & Hu, J. (2023). Matching analysis of carbon-ceramic brake discs for high-speed trains. Applied Sciences, 13(7), 4532. https://doi.org/10.3390/app13074532

Kepekci, H., & Ağca, M. E. (2023). Numerical investigation of the thermal effect of material variations on the brake disc. International Journal of Pioneering Technology and Engineering, 2(02), 135–141. https://doi.org/10.56158/jpte.2023.52.2.02.