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Abstract
To investigate the causes of crack initiation and propagation in brake discs, a comprehensive analysis of surface cracks was conducted using macroscopic observation, metallographic observation, scanning electron microscopy, and microhardness testing. The results revealed that the internal structure of the brake disc material consists mainly of pearlite and a small amount of ferrite. Near the friction surface, the internal structure undergoes grain refinement and the formation of a small amount of granular pearlite, with a microhardness range of 350 ∼ 410 HV. Based on metallographic observations, it is evident that there are loose defects within the brake disc. When the brake disc is subjected to external loads and thermal stress, stress concentration occurs around these defects, initiating cracks and their outward propagation, thereby accelerating the crack propagation rate. The crack growth exhibits a combination of transgranular and intergranular characteristics. Analysis of the crack width in the brake disc reveals that the width of the radial primary cracks is approximately three times that of the micro-cracks, and the depth of the micro-cracks is relatively shallow, with a maximum depth of 4 mm. In contrast, the primary crack extends to a depth of 9 mm. This implies that the failure of the brake disc is associated with the extension and deepening of cracks.
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