Revolutionizing brake calipers with Brembo for the EU’s Life-CRAL project

Brembo is a world leader and pioneer in disc brake technology for the automotive industry. Their innovation-oriented approach has led to an impressive catalog of brakes for a wide range of vehicles.

This project would require a novel approach: using a semi-solid metal (SSM), aluminum, injected with laminar flow and high specific pressure through vertical injection technology. SSM requires direct injection into the container, with strictly controlled cooling to obtain a highly viscous thixotropic slurry. The slurry would then need to be immediately transferred beneath the closed mold and injected using a hydraulic piston via a bottom-up path.

We designed a unique 1000-ton vertical short stroke die-casting press from the bottom up. Installed on Brembo’s premises, the press was created to dose, prepare, and inject the alloy directly into the injection containers.

The collaboration yielded a revolutionary semi-solid metal (SSM) processing line. It is now possible to produce top-tier, lightweight cast components for cars from recycled low-grade aluminum alloys.

This method is safe and environmentally friendly: using recycled semi-solid aluminum with our plant decreases CO2 emissions by 94%, reduces energy and cuts the resource consumption associated with primary aluminum extraction, refining, and production.

Partnering with Cannon in 2016, Brembo began the Life-CRAL project. Sponsored by the EU, the project’s goal was to create an innovative production line for high-quality brake calipers using a secondary aluminum alloy, derived from recycled material. The result would need to have a mechanical strength similar to that obtained with a primary alloy and a highly homogeneous microstructure.

• 1000-ton VerticAL rheocasting line