Patent No. EP4267865 (titled "Brake Disc With Steel Layer With Reduced Nickel Content And Manufacturing Method") was filed by Brembo on Dec 23, 2021. The application was issued on Oct 1, 2025.
A brake disc comprises a braking band made of steel or gray cast iron, featuring two opposite braking surfaces. The disc includes a base layer covering at least one braking surface, characterized by a steel composition with a nickel content of at most 15%. To compensate for reduced nickel and maintain mechanical strength, corrosion resistance, and thermal performance, the base layer steel may contain 0.5% to 10% molybdenum and 0.5% to 5% manganese. Embodiments may include a nickel-free martensitic steel base layer (10-15% Cr, $\le$1% Si, $\le$4% Mn, 0.16-0.5% C, balance Fe). Optional configurations include an intermediate steel layer (nickel-free or $\le$15% Ni) or auxiliary ferritic-nitrocarburization and ferroalumination layers interposed between the braking band, base layer, or protective surface coating.

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