ecoCast

ecoCast serves a unique function: it acts as a tribological homogenizer between the pad and the disc. Being composed of the same base material as the rotor (certified EN GJL 250 grey cast iron), its main roles are:

• Creating a "Friendly" Contact: It facilitates the formation of a stable and compatible transfer layer (tribofilm), reducing the aggressiveness of the pad-disc contact.
• High-Temperature Self-Lubrication: The natural graphite flakes present in ecoCast's microstructure are released during friction, acting as a high-performance solid lubricant that stabilizes the coefficient of friction (µ) and dampens vibrations.
• NVH Improvement: Thanks to the excellent damping capacity of graphite and its softer matrix (pearlite/ferrite), ecoCast absorbs energy and dissipates it as heat, significantly reducing the propensity for noise and vibration generation (NVH).

The difference is conceptual:

• Hard Abrasives: While a hard abrasive aggressively cleans the disc surface through a "cutting" mechanism, ecoCast generates very mild cohesive wear. Its hardness (160-230 HB) is similar to that of the disc, so it does not "attack" it but rather "integrates" into the surface, protecting it and extending its service life.
• Non-Ferrous Chips: Brass and bronze function primarily as thermal conductors. ecoCast, although with lower conductivity, provides a superior tribological benefit through graphite self-lubrication, making it especially valuable in Low-Copper or Copper-Free formulations. For this reason, ecoCast is an excellent substitute for brass in many applications, offering cost and NVH performance benefits.

The key lies in RIMSA's metallurgical control and manufacturing process:

• Controlled Microstructure: ecoCast is derived from a certified EN GJL 250 grey cast iron, featuring a pearlite and ferrite microstructure. This makes it significantly softer and less abrasive than white cast iron grits (600 HB), which contain cementite (Fe₃C), an extremely hard phase that causes severe disc wear.
• Chip Morphology: RIMSA's dry process generates particles with a chip-like morphology, which disperse and compact homogeneously in the mix. Grits typically have an equiaxial (granular) morphology that does not integrate in the same way.
• Purity and Consistency: As a controlled manufactured product, ecoCast guarantees a stable chemical composition and is free of impurities, ensuring predictable performance from batch to batch.

ecoCast is particularly valuable in:

• Copper-Free Heavy-Duty Applications: Where robustness and disc life are critical. Its combination with steel fibers helps protect the disc from excessive wear.
• NAO Formulations for Original Equipment (OE): Where low noise and vibration (NVH) and minimal disc wear are sought.
• As a substitute for brass: In formulations looking to reduce copper content and optimize costs without sacrificing friction stability.

The flake graphite within the grey cast iron matrix is an exceptional solid lubricant. During the braking process:

• It is released at the interface: Creating a lubricating layer that reduces direct metal-to-metal contact.
• It dampens vibrations: It absorbs the energy of high-frequency vibrations, which are the main cause of squeal noise.
• It stabilizes friction: It prevents the "stick-slip" phenomenon at a microscopic level, resulting in a more stable coefficient of friction throughout the braking event.