Evaluating Surface Roughness (Sr) (Max. 80 Micrometer Permitted)

Information 

• An increase in surface roughness impairs smoothness of braking (rubbing, shaking in steering wheel, scraping noises) and increases brake pad wear. 
• With a roughness (Sr) value of > 80 μm (> 80 micrometer), a precautionary parts replacement is required. 

The assessment is carried out visually, based on the diagram. Two illustrations of the same peak-to valley surface roughness (views 1 and 2) help to make a better assessment.

1. Brake discs that are OK: 
   1. 1.1. Surface roughness (Sr) = 6 μm -see Fig 1- (view 1)
      Fig 1: Identifying PCCB Surface Roughness (Sr) = 6 Micrometer (View 1)

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      Surface roughness (Sr) = 6 μm -see Fig 2- (view 2)

      New brake disc. Illustration is used to enable better classification.

      The early stages of roughness are indicated by burnt-out carbon fibres on the surface of an otherwise intact, semi-matt surface.

      The surface feels smooth.

      Fig 2: Identifying PCCB Surface Roughness (Sr) = 6 Micrometer (View 2)

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   2. 1.2. Surface roughness (Sr) = 56 μm -see Fig 3- (view 1)
      Fig 3: Identifying PCCB Surface Roughness (Sr) = 56 Micrometer (View 1)

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      Surface roughness (Sr) = 56 μm -see Fig 4- (view 2)

      In the advanced stages of fibre burn-out and the initial destruction of the Si and SiC 'matrix', the depressions have become more pronounced. Large sections of the surface are still intact, the depressions form an even, fine-grained pattern.

      The surface still feels matt, however, and the roughness is not yet pronounced.

      No replacement necessary!

      Fig 4: Identifying PCCB Surface Roughness (Sr) = 56 Micrometer (View 2)

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   3. 1.3. Surface roughness (Sr) = 72 μm -see Fig 5- (view 1)
      Fig 5: Identifying PCCB Surface Roughness (Sr) = 72 Micrometer (View 1)

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      Surface roughness (Sr) = 72 μm -see arrow-  (view 2)

      Borderline disc, which can still just be evaluated as OK. As a result of more advanced damage to the surface, the depressions are larger, and above all deeper, compared with the previous surface condition.

      On the one hand, the more extensive roughness is noticeable (only when a comparison is made); on the other hand, however, like before, "only" depressions are observed.

      Replacement not yet necessary!

      Fig 6: Identifying PCCB Surface Roughness (Sr) = 72 Micrometer (View 2)

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2. Worn brake discs: 
   1. 2.1. Surface roughness (Sr) = 108 μm -see Fig 7- (view 1)
      Fig 7: Identifying PCCB Surface Roughness (Sr) = 108 Micrometer (View 1)

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      Surface roughness (Sr) = 108 μm -see Fig 8- (view 2)

      Worn surface. Advanced wear has led to a situation where only the remains of the original surface are left.

      It is clear that the roughness is caused not only by depressions but also by bumps.

      Replace brake discs! To do this, please observe the relevant information → Replacing brake discs (notes/decision-making aid)  .

      In general, the following applies: Brake discs must be replaced if the surface roughness (Sr) is > 80 μm!

      Fig 8: Identifying PCCB Surface Roughness (Sr) = 108 Micrometer (View 2)

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3. Worn brake discs (special cases): 
   1. 3.1. Surface roughness (Sr) = 108 μm, as in the case of the previous disc, but with the remainder of the original friction surface -arrow-  .

      Replace brake discs! To do this, please observe the relevant information → Replacing brake discs (notes/decision-making aid)  .

      In general, the following applies: Brake discs must be replaced if the surface roughness (Sr) is > 80 μm!

      Fig 9: Identifying PCCB Surface Roughness (Sr) = 108 Micrometer

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 3.2. Surface roughness (Sr) = 72 μm. Borderline disc, identified by the roughness, but also by the indication of wear and associated surface fractures -arrows-  , > 1 cm² .

      Replace brake discs! To do this, please observe the relevant information → Replacing brake discs (notes/decision-making aid)  .

      Fig 10: Locating PCCB Brake Disc Wear

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.