The Garage 364

NEWS
Industry warned over
POOR QUALITY BRAKE CALIPERS
following independent study
29 defects
found in new
caliper brands
entering the
aftermarket
The automotive industry is being
urged to question the quality and
safety of calipers entering the
aftermarket, following an independent
study by Brake Engineering.
The braking specialist commissioned
an independent company to evaluate the
quality and subsequent performance of
calipers being sold into the independent
automotive aftermarket.
Three new brands of calipers were
tested and all failed to meet standards
and critical tolerances set by original
equipment manufacturers (OEMs), with
all three found to have used lower-grade
material.
In total, 29 structural and mechanical
defects affecting the performance of
calipers were detected.
While aesthetically these calipers look
‘fine’, under closer testing all units were
shown to have ‘porosities’ (holes) and
oxides in the material and all had partly
inhomogeneous microstructures.
This could result in weakening of the
unit and could potentially compromise the
braking performance when braking under
normal driving conditions.
The test looked at six areas of the
calipers including: Machined radius finger
(bridge), caster radius finger (bridge),
caster radius finger (pot), machined radius
(chamfer), radius at step of piston bore
and, radius at bottom of piston bore.
The tests focused on: Material
Chemical Composition, examining failure
to conform with OE standards normal
lifecycle operation, severely weakening
casting; structure and mechanical
properties, where porosities can cause
higher vibrations, increased noise level
and lack of pedal consistency leading to
catastrophic brake failure; and, rubber
and seal quality, where inefficiencies could
lead to cracks and component failure.
Calipers, as part of a vehicle’s braking
system, are safety critical products and
therefore any products that fail to meet
the original specification of the product
could have severe and potential hazardous
consequences, warns Brake Engineering.
Mark Hallam, Brake Engineering
marketing manager, said: “The results
of the independent test are alarming
for the aftermarket, especially following
the trade’s successful MOT campaign
to maintain safety standards. Calipers
entering the market may appear fit for
purpose. However, their performance has
been found to be severely questionable
with structures potentially leading to
catastrophic failure.”
6 THE GARAGE
6, News Brake Calipers.indd 1 01/07/2024 16:12