Disc Failure Research Articles

Fatigue Failure Of Steam Turbine Discs - A Centenary Tribute To Wilfred Campbell

Abstract The year 2024 marks one hundred years since Wilfred Campbell published his landmark work on vibrational analysis of rotating disc following a series of disc failures in steam turbines. Despite the absence of advanced engineering analytical tools, Campbell came up with an elegant method to visually demonstrate and capture the mode shapes in rotating discs. The first part of this paper reviews Campbell?s life and analytical and experimental work in this area. Regardless of the current advanced engineering capabilities to predict nodal shapes in turbine discs, turbine discs still experience failures related to vibration. The second part of the paper discusses a recent case study where a turbine disc failure occurred as a result of vibration. The discussion includes metallurgical root cause failure analysis and engineering analysis to predict the vibrational characteristics. Metallurgical failure analysis confirmed that the primary mode of failure was fatigue and did not have any issues with the disc material or its mechanical properties. Finite element modeling and analysis were used for the engineering analysis to predict the natural frequencies of the bladed-disc. The engineering analysis showed the evidence of potential resonance, and the failure was related to nodal vibration issues.

Finite Element Method analysis application in identifying the causes of brake disc failure

This article presents the results of brake disc tests aimed at identifying the causes of its failure. The first part of the article presents an analysis of the damageability of selected vehicle components, which showed that among the reported failures, the most failure was the braking system. The assessment of the brake disc worn "properly" as a result of operation and the deformed brake disc after a very short period of operation, which was the subject of further analysis. The next part of the article presents issues related to the modeling of thermal loads, and then, trying to assess and search for the cause of abnormal wear of the brake system element, the use of the Finite Element Method for the analysis and assessment of brake disc wear was proposed. In the final part of the article, conclusions and directions for further work were formulated.

Improved Cauchy Reed-Solomon Codes for Cloud Data Retrieval and Secured Data Storage using Role-Based Cryptographic Access and forensic investigation

Doling out client consent strategies to PC frameworks presents a huge test in guaranteeing legitimate approval, especially with the development of open frameworks and scattered stages like the cloud. RBAC has turned into a broadly involved strategy in cloud server applications because of its versatility. Granting access to cloud-stored data for investigating potential wrongdoings is crucial in computer forensic investigations. In cases where the cloud service provider's reliability is questionable, maintaining data confidentiality and establishing an efficient procedure for revoking access upon credential expiration is essential. As storage systems expand across vast networks, frequent component failures require stronger fault tolerance measures. Our work secure data-sharing system combines role (Authorized) based access control and AES encryption technology to provide safe key distribution and data sharing for dynamic groups. Data recovery entails protecting data dispersed over distributed systems by storing duplicate data and applying the erasure code technique. Erasure coding strategies, like Reed-Solomon codes, guarantee disc failure robustness while cutting down on data storage expenses dramatically. They do, however, also result in longer access times and more expensive repairs. Consequently, there has been a great deal of interest in academic and business circles for the investigation of novel coding strategies for cloud storage systems. The objective of this study is to present a novel coding method that utilizes the intricate Cauchy matrix in order to improve Reed-Solomon coding efficiency and strengthen fault tolerance.

Numerical simulation and mechanism analysis of thermal fatigue crack for low-alloy steel brake disc of high-speed train

ABSTRACT High-speed train brake discs face severe service conditions and subsequently risk of material failure during emergency braking. Thermal fatigue cracking is a major concern leading to catastrophic disc failure and is regarded as a primary service bottleneck in rapid rail transportation. Our proposed work establishes a numerical prediction model to estimate thermal fatigue crack initiation and propagation in low-alloy steel. We used a modified Cockcroft-Latham criterion and material property tests to determine the critical crack initiation value. Through numerical simulations and in-situ experiments, we observed plastic deformation at the median temperature of the thermal fatigue cycle and found that tailored material composition improves brake disc fatigue performance. This research aims to enhance understanding of the cracking mechanism and improve the reliability of brake systems for high-speed trains.

Non-enzymatic glycation increases the failure risk of annulus fibrosus by predisposing the extrafibrillar matrix to greater stresses.

Growing clinical evidence suggests a correlation between diabetes and more frequent and severe intervertebral disc failure, partially attributed to accelerated advanced glycation end-products (AGE) accumulation in the annulus fibrosus (AF) through non-enzymatic glycation. However, in vitro glycation (i.e., crosslinking) reportedly improved AF uniaxial tensile mechanical properties, contradicting clinical observations. Thus, this study used a combined experimental-computational approach to evaluate the effect of AGEs on anisotropic AF tensile mechanics, applying the finite element models (FEM) to complement experimental testing and examine difficult-to-measure subtissue-level mechanics. Methylglyoxal-based treatments were applied to induce three physiologically relevant AGE levels in vitro. Models incorporated crosslinks by adapting our previously validated structure-based FEM framework. Experimental results showed that a threefold increase in AGE content resulted in a ∼55% increase in AF circumferential-radial tensile modulus and failure stress and a 40% increase in radial failure stress. Failure strain was unaffected by non-enzymatic glycation. Adapted FEMs accurately predicted experimental AF mechanics with glycation. Model predictions showed that glycation increased stresses in the extrafibrillar matrix under physiologic deformations, which may increase tissue mechanical failure or trigger catabolic remodeling, providing insight into the relationship between AGE accumulation and increased tissue failure. Our findings also added to the existing literature regarding crosslinking structures, indicating that AGEs had a greater effect along the fiber direction, while interlamellar radial crosslinks were improbable in the AF. In summary, the combined approach presented a powerful tool for examining multiscale structure-function relationships with disease progression in fiber-reinforced soft tissues, which is essential for developing effective therapeutic measures. STATEMENT OF SIGNIFICANCE: : Increasing clinical evidence correlates diabetes with premature intervertebral disc failure, likely due to advanced glycation end-products (AGE) accumulation in the annulus fibrosus (AF). However, in vitro glycation reportedly increases AF tensile stiffness and toughness, contradicting clinical observations. Using a combined experimental-computational approach, our work shows that increases in AF bulk tensile mechanical properties with glycation are achieved at the risk of exposing the extrafibrillar matrix to increased stresses under physiologic deformations, which may increase tissue mechanical failure or trigger catabolic remodeling. Computational results indicate that crosslinks along the fiber direction account for 90% of the increased tissue stiffness with glycation, adding to the existing literature. These findings provide insight into the multiscale structure-function relationship between AGE accumulation and tissue failure.

An appraisal of dwell sensitive fatigue in Ti-6Al-4V and the governing role of inhomogeneous micro-texture

The fact that the α/β titanium alloy Ti-6Al-4V is sensitive to cold dwell loading regimes has recently been endorsed by a combination of evidence gathered from fatigue studies performed on laboratory scale specimens and the findings of a failure investigation into an in-service fan disc failure. This work confirms that Ti-6Al-4V can demonstrate dwell characteristics under fatigue loading, subject to the microstructure and micro-texture developed during thermo-mechanical processing. Additional fatigue data are presented to support this conclusion, together with detailed metallographic and crystallographic characterisation to identify the factors controlling inhomogeneous strength, stress distribution and the crack initiation process on the micro to macro scale.

Fracture Process and Failure Mode of Brazilian Discs with Cracks of Different Angles: A Numerical Study

In order to determine the effect of internal cracks on the tensile failure of materials, a hybrid finite–discrete element method was used to analyze the Brazilian disc test with cracks of different angles. When the pre-crack angle is between 0° and 60°, the wing crack is initiated from the pre-crack end. When the pre-crack is 90°, the crack initiated from the pre-crack center. When the pre-crack angle is between 0° and 60°, the maximum principal stress and plastic strain are concentrated at the pre-crack end. When the pre-crack angle is 90°, the maximum principal stress and plastic strain are concentrated in the pre-crack center. As the crack angle increased from 0° to 90°, the failure mode of Brazilian discs with cracks transits from splitting into two parts to splitting into four parts. The influence of crack length is further studied. When the crack length is less than 5 mm, the crack angle has little influence on the disc failure mode; Brazilian discs with cracks of different angles undergoes splitting failure along the loading axis. When the crack length is larger than 5 mm, the crack angle has a great effect on the disc failure mode.

Injectable Cell-Laden Nanofibrous Matrix for Treating Annulus Fibrosus Defects in Porcine Model: An Organ Culture Study.

Lower back pain commonly arises from intervertebral disc (IVD) failure, often caused by deteriorating annulus fibrosus (AF) and/or nucleus pulposus (NP) tissue. High socioeconomic cost, quality of life issues, and unsatisfactory surgical options motivate the rapid development of non-invasive, regenerative repair strategies for lower back pain. This study aims to evaluate the AF regenerative capacity of injectable matrix repair strategy in ex vivo porcine organ culturing using collagen type-I and polycaprolactone nanofibers (PNCOL) with encapsulated fibroblast cells. Upon 14 days organ culturing, the porcine IVDs were assessed using gross optical imaging, magnetic resonance imaging (MRI), histological analysis, and Reverse Transcriptase quantitative PCR (RT-qPCR) to determine the regenerative capabilities of the PNCOL matrix at the AF injury. PNCOL-treated AF defects demonstrated a full recovery with increased gene expressions of AF extracellular matrix markers, including Collagen-I, Aggrecan, Scleraxis, and Tenascin, along with anti-inflammatory markers such as CD206 and IL10. The PNCOL treatment effectively regenerates the AF tissue at the injury site contributing to decreased herniation risk and improved surgical outcomes, thus providing effective non-invasive strategies for treating IVD injuries.

Evaluation of Thermal Fatigue Life and Crack Morphology in Brake Discs of Low-Alloy Steel for High-Speed Trains.

Effective braking in high-speed trains is one of the major bottlenecks in expediting the technology and possibilities to improve speed. Although substantial progress has been made to increase operating speed, perhaps, thermal fatigue cracking in brake discs is a primary constraint so far. Thermal fatigue cracking is the major cause of brake disc failure in high-speed trains, especially trains with a speed of 350 km/h or above. In this study, new material composition is proposed for brake discs of high-speed trains. A comprehensive investigation is presented based on fatigue crack initiation and propagation, along with wear and micro-hardness characterization. Thermal fatigue tests at various thermal cycles between 20 ℃ and 700 ℃ were performed and the experimental results are compared with fatigue properties of a commercial brake disc material. An experimental trial revealed that thermal cracks normally initiate and propagate along the oxidized grain boundaries; nevertheless, crack propagation is restricted by the fine precipitates and lath structure of martensitic. Moreover, crack length at the initiation and propagation stage is predicted through crack growth rate and favorable grain size in the crack vicinity. Thermal fatigue life can be improved by dictating the microstructure and precipitate morphology of cast steel by tailoring the alloying composition.

Comparative Study on Thermal Analysis of Disc Brake Using ANSYS Simulation

The objective of this paper is to find a suitable material for disc brakes that can dissipate heat very fast to the environment than others. They are subjected to wear and tear, which might have an impact on their performance. The simulation findings will help us figure out the temperature, pressure, and heat that can be withstand at its maximum. If it manages to dissipate heat properly it can avoid the distortion, which will be produced in the disc, which leads to thermal cracking of the disc leading to disc failure. To eliminate such flaws, we need to develop a disc brake material that can endure a specific level of heat and friction while maintaining its efficiency over time. In this work, 3 different disc brake materials, namely Al356, cast iron, and SS420, are chosen for thermal analysis by using ANSYS simulations and the results will be compared among.

Case study of accelerated wear of brake discs made of grey cast iron characterized by increased thermal stability

In this paper, the subject of the analysis is Rotinger High Performance brake disc, characterized by increased thermal resistance, which is a result of adequate design and material solutions. However, despite declared performance, the analyzed discs suffered accelerated wear over a period of about 20 months. The aim of this study was to assess the causes of the disc failure. As a result, it was showed that the applied material solution still does not differ from standard ones. According to the authors of this paper, an appropriate procedure to improve resistance to thermal fatigue is, among others, changing the shape of graphite precipitates from flake to spheroidal.

Torque- and Muscle-Driven Flexion Induce Disparate Risks of In Vitro Herniation: A Multiscale and Multiphasic Structure-Based Finite Element Study.

The intervertebral disc is a complex structure that experiences multiaxial stresses regularly. Disc failure through herniation is a common cause of lower back pain, which causes reduced mobility and debilitating pain, resulting in heavy socioeconomic burdens. Unfortunately, herniation etiology is not well understood, partially due to challenges in replicating herniation in vitro. Previous studies suggest that flexion elevated risks of herniation. Thus, the objective of this study was to use a multiscale and multiphasic finite element model to evaluate the risk of failure under torque- or muscle-driven flexion. Models were developed to represent torque-driven flexion with the instantaneous center of rotation (ICR) located on the disc, and the more physiologically representative muscle-driven flexion with the ICR located anterior of the disc. Model predictions highlighted disparate disc mechanics regarding bulk deformation, stress-bearing mechanisms, and intradiscal stress-strain distributions. Specifically, failure was predicted to initiate at the bone-disc boundary under torque-driven flexion, which may explain why endplate junction failure, instead of herniation, has been the more common failure mode observed in vitro. By contrast, failure was predicted to initiate in the posterolateral annulus fibrosus under muscle-driven flexion, resulting in consistent herniation. Our findings also suggested that muscle-driven flexion combined with axial compression could be sufficient for provoking herniation in vitro and in silico. In conclusion, this study provided a computational framework for designing in vitro testing protocols that can advance the assessment of disc failure behavior and the performance of engineered disc implants.

How annulus defects can act as initiation sites for herniation

PurposeBoth posture and loading rate are key factors in the herniation process and can determine the mechanism of disc failure. The aim of this study was to test the hypothesis that disruption visible with HR-MRI post-testing corresponds with microstructural features and further elucidate the mechanism by which this disruption weakens the disc. This will enable us to gain new insights into the herniation process.MethodsThirty ovine lumbar spinal segments were subjected to combinations of four loading conditions (0–12° flexion, 0–9° lateral bending, 0–4° axial rotation, 0–1500 N axial compression) for 1000 loading cycles at 2 Hz in a dynamic disc loading simulator. The discs were scanned in an ultra-high field MRI (11.7 T) then examined using brightfield microscopy to examine their microstructure.ResultsFour discs herniated and seven discs suffered nucleus displacement. These discs contained pre-existing defects in the central posterior annulus. Generally, following testing discs contained more posterior annulus disruption, Microstructural investigation revealed there was clear correspondence between HR-MRI and microstructural observations, and that the mid-outer annular-endplate junction had failed in all discs examined in this study.ConclusionsWhile all discs suffered outer annulus damage, only the discs containing pre-existing defects herniated. These pre-existing defects weakened the inner and mid annulus, allowing herniation to occur once the mid and outer annular wall was compromised. We propose this can occur during the degenerative cascade.

Non-enzymatic glycation of annulus fibrosus alters tissue-level failure mechanics in tension

Advanced-glycation end products (AGEs) are known to accumulate in biological tissues with age and at an accelerated rate in patients with diabetes and chronic kidney disease. Clinically, diabetes has been linked to increased frequency and severity of back pain, accelerated disc degeneration, and an increased risk of disc herniation. Despite significant clinical evidence suggesting that diabetes-induced AGEs may play a role in intervertebral disc failure and substantial previous work investigating the effects of AGEs on bone, cartilage, and tendon mechanics, the effects of AGEs on annulus fibrosus (AF) failure mechanics have not yet been reported. Thus, the aim of this study was to determine the relationship between physiological levels of AGEs and AF tensile mechanics at two distinct loading rates. In vitro glycation treatments with methylglyoxal were applied to minimize changes in tissue hydration and induce two distinct levels of AGEs based on values measured from human AF tissues.In vitro glycation increased modulus by 48–99% and failure stress by 45–104% versus control and decreased post-failure energy absorption capacity by 15–32% versus control (ANOVA p < 0.0001 on means; range given across two loading rates and glycation levels). AGE content correlated strongly with modulus (R = 0.74, p < 0.0001) and failure stress (R = 0.70, p < 0.0001) and moderately with post-failure energy absorption capacity (R = 0.62, p < 0.0001). Failure strain was reduced by 10–17% at the high-glycation level (ANOVA p = 0.01). Tissue water content remained near or just above fresh-tissue levels for all groups. The alterations in mechanics with glycation reported here are consistent with trends from other connective tissues but do not fully explain the clinical predisposition of diabetics to disc herniation. The results from this study may be used in the development of advanced computational models that aim to study disc disease progression and to provide a deeper understanding of altered structure-function relationships that may lead to tissue dysfunction and failure with aging and disease.

Modelling mode I failure at crack tip with verifications using digital image correlation

Background: Linear elastic fracture mechanics (LEFM) applies to sharp cracks, although crack sites such as holes and slots are often blunt cracks with nonzero widths. The advancement in finite element method (FEM) has enabled the calculation of stress intensity factor (SIF) for unstable crack growth prediction, regardless of crack shape and size, but the calculations often differ from contour to contour. Hence, the purpose of this work is to determine if SIFs computed using commercial FEM have experimentally verifiable advantages over the traditional stress-based modelling approaches in predicting Mode I brittle failure at blunt crack tip. Methods: Experiments and simulations were conducted on brittle Poly(methyl methacrylate) (PMMA) plastic to compare the actual and predicted strain fields and SIFs at crack tip, and the critical force at which unstable crack growth initiates. A centrally straight cracked Brazilian disc made of PMMA was subjected to purely Mode I fracture. Its strain fields were measured from deformed speckle patterns using digital image correlation software. The same disc was modelled using plane stress model in FEM. By applying the critical force, SIFs were then computed using ANSYS pre-meshed crack method at different contours away from the crack tip. The effects of element type, mesh size and crack width on the simulated SIFs were investigated. Results: It was found that the experimental critical load agreed well with LEFM prediction based on PMMA fracture toughness in published literature. Disc failure happened at the first sign of tensile yield at the crack tip in the finite element model with a triangle mesh. Digital image correlation clearly shows the occurrence of unstable crack growth at critical force. It also shows comparable far field strain responses to the FEM model. Conclusions: The computed SIFs were inconsistent, and their usefulness in predicting unstable crack growth requires further investigation.

Tenomodulin and Chondromodulin-1 Are Both Required to Maintain Biomechanical Function and Prevent Intervertebral Disc Degeneration.

The underlying mechanisms and molecular factors influencing intervertebral disc (IVD) homeostasis and degeneration remain clinically relevant. Tenomodulin (Tnmd) and chondromodulin (Chm1) are antiangiogenic transmembrane glycoproteins, with cleavable C-terminus, expressed by IVD cells that are implicated in the onset of degenerative processes. We evaluate the organ-level biomechanical impact of knocking out Tnmd alone, and Tnmd and Chm1, simultaneously. Caudal (c5-8) and lumbar vertebrae (L1-4) of skeletally mature male and female 9-month-old wildtype (WT), Tnmd knockout (Tnmd-/-), and Tnmd/Chm1 double knockout (Tnmd-/-/Chm-/-) mice were used (n = 9-13 per group). Disc height index (DHI), histomorphological changes, and axial, torsional, creep, and failure biomechanical properties were evaluated. Differences were assessed by one-way ANOVA with post hoc Bonferroni-corrected comparisons (P < 0.05). Tnmd-/-/Chm1-/- IVDs displayed increased DHI and histomorphological scores that indicated increased IVD degeneration compared to the WT and Tnmd-/- groups. Double knockout IVDs required significantly less torque and energy to initiate torsional failure. Creep parameters were comparable between all groups, except for the slow time constant, which indicated faster outward fluid flow. Tnmd-/- IVDs lost fluid faster than the WT group, and this effect was amplified in the double knockout IVDs. Knocking out Tnmd and Chm1 affects IVD fluid flow and organ-level biomechanical function and therefore may play a role in contributing to IVD degeneration. Larger effects of the Tnmd and Chm1 double knockout mice compared to the Tnmd single mutant suggest that Chm1 may play a compensatory role in the Tnmd single mutant IVDs.

A microstructure-based model for a full lamellar-interlamellar displacement and shear strain mapping inside human intervertebral disc core

The determinant role of the annulus fibrosus interlamellar zones in the intervertebral disc transversal and volumetric responses and hence on their corresponding three-dimensional conducts have been only revealed and appreciated recently. Their consideration in disc modeling strategies has been proven to be essential for the reproduction of correct local strain and displacement fields inside the disc especially in the unconstrained directions of the disc. In addition, these zones are known to be the starting areas of annulus fibrosus circumferential tears and disc delamination failure mode, which is often judged as one of the most dangerous disc failure modes that could evolve with time leading to disc hernia. For this latter reason, the main goal of the current contribution is to incorporate physically for the first time, the interlamellar zones, at the scale of a complete human lumbar intervertebral disc, in order to allow a correct local vision and replication of the different lamellar-interlamellar interactions and an identification of the interlamellar critical zones. By means of a fully tridimensional chemo-viscoelastic constitutive model, which we implemented into a finite element code, the physical, mechanical and chemical contribution of the interlamellar zones is added to the disc. The chemical-induced volumetric response is accounted by the model for both the interlamellar zones and the lamellae using experimentally-based fluid kinetics. Computational simulations are performed and critically discussed upon different simple and complex physiological movements. The disc core and the interlamellar zones are numerically accessed, allowing the observation of the displacement and shear strain fields that are compared to direct MRI experiments from the literature. Important conclusions about the correct lamellar-interlamellar-nucleus interactions are provided thanks to the developed model. The critical interlamellar spots with the highest delamination potentials are defined, analyzed and related to the local kinetics and microstructure.

A Robust Multiscale and Multiphasic Structure-Based Modeling Framework for the Intervertebral Disc.

A comprehensive understanding of multiscale and multiphasic intervertebral disc mechanics is crucial for designing advanced tissue engineered structures aiming to recapitulate native tissue behavior. The bovine caudal disc is a commonly used human disc analog due to its availability, large disc height and area, and similarities in biochemical and mechanical properties to the human disc. Because of challenges in directly measuring subtissue-level mechanics, such as in situ fiber mechanics, finite element models have been widely employed in spinal biomechanics research. However, many previous models use homogenization theory and describe each model element as a homogenized combination of fibers and the extrafibrillar matrix while ignoring the role of water content or osmotic behavior. Thus, these models are limited in their ability in investigating subtissue-level mechanics and stress-bearing mechanisms through fluid pressure. The objective of this study was to develop and validate a structure-based bovine caudal disc model, and to evaluate multiscale and multiphasic intervertebral disc mechanics under different loading conditions and with degeneration. The structure-based model was developed based on native disc structure, where fibers and matrix in the annulus fibrosus were described as distinct materials occupying separate volumes. Model parameters were directly obtained from experimental studies without calibration. Under the multiscale validation framework, the model was validated across the joint-, tissue-, and subtissue-levels. Our model accurately predicted multiscale disc responses for 15 of 16 cases, emphasizing the accuracy of the model, as well as the effectiveness and robustness of the multiscale structure-based modeling-validation framework. The model also demonstrated the rim as a weak link for disc failure, highlighting the importance of keeping the cartilage endplate intact when evaluating disc failure mechanisms in vitro. Importantly, results from this study elucidated important fluid-based load-bearing mechanisms and fiber-matrix interactions that are important for understanding disease progression and regeneration in intervertebral discs. In conclusion, the methods presented in this study can be used in conjunction with experimental work to simultaneously investigate disc joint-, tissue-, and subtissue-level mechanics with degeneration, disease, and injury.

Investigation on friction and wear performance of laser cladding Ni-based alloy coating on brake disc

Wear is the leading cause of brake disc failure. However, laser cladding technology provides a fast and environmentally friendly method to repair brake disc damage caused by wear. In this paper, Ni-based alloy powder was used to prepare the coating on the surface of the brake disc to improve its wear resistance, and the coating prepared by laser cladding was systematically studied. The main phases of the coating were γ-Ni and Ni3C, which were the main reasons for increasing the hardness and elastic modulus. The microstructure of the coating is compact. With the change of the solidification rate and temperature gradient, the microstructure changed from columnar to cellular, dendritic and equiaxed. By comparing the wear volume of the coating and substrate before and after wear, it was found that the coating has better wear resistance (about 1.5 times that of the substrate). Besides, the coating also has good oxidation resistance. The oxidation film formed during the wear process of the coating is beneficial to inhibit the regeneration of oxide. Therefore, according to the test results the laser cladding Ni-based coating is an effective means to improve the tribological properties of the brake disc.

Thermal analysis of brake disc of an automobile

One of the most effective protective features of modern vehicles is the braking system. The brake absorbs kinetic energy of the rotating parts (Wheels) and dissipates this energy into the surrounding atmosphere in the form of heat energy. Disc brake is the recent trend in automobile which dissipates the heat faster than the conventional brakes but if hard braking is done, thermal stresses in the brake disc are induced, leading to excessive heat generation, which further produces distortion and thermal cracking of the disc leading to disc failure. The main objective of this work is to compare four different materials viz. Aluminium Alloy, Ceramics, Grey Cast Iron and Titanium Alloy for disc brake and to identify the most suitable material for brake disc. The model of disc was prepared using the dimensions of an existing Maruti car and its transient state analysis is done using SOLIDWORKS. After the analysis the value of heat flux distribution and von-Mises stress for the selected profile was 1.577e+05 W/m2 and 7.920e+09 N/mm2 for Aluminium alloy, 4.358e+05 W/m2 and 9.806e+09 N/mm2 for Ceramics, 9.747e+05 W/m2 and 1.218e+10 N/mm2 for Grey Cast Iron and 9.224e+05 W/m2 and 8.292e+09 N/mm2 for Titanium alloy. It was noted that the heat flux dissipation is more and von-Mises stress is less for the Grey Cast Iron and it is suitable for the manufacturing purpose.