Latest news with #brakedust
Auto Blog
5 days ago
- Automotive
- Auto Blog
Tired of Brake Dust? Brembo's Greentell System Could Be Your Solution
As Europe clamps down on brake emissions, Brembo's Greentell rotors offer a high-tech solution that could reshape the future of friction brakes. Brake dust isn't just ugly — it's harmful If you've ever seen silver wheels turned gray from brake dust, you've witnessed a small part of a much larger problem. That dust doesn't just settle on wheels; it enters the air and, eventually, our lungs. It's why the European Union is targeting brake particulate emissions under its upcoming Euro 7 standards, set to take effect next year. These rules cap brake particle emissions at 7 milligrams per kilometer, dropping to 3 mg/km by 2035. Even EVs, which rely more on regenerative braking, aren't entirely off the hook. Greentell is Brembo's answer to Euro 7 Italian brake giant Brembo believes it has a solution: a new line of rotors called Greentell, combining 'green' and 'intelligent' in one slightly awkward but descriptive name. The real innovation lies in how they're made. Greentell rotors are treated with a proprietary coating applied through Laser Metal Deposition (LMD), an additive manufacturing process that uses powdered metals and lasers to 'print' a surface layer onto the brake disc. This dual-layer coating dramatically cuts down on the amount of particulate matter released during braking. Massive dust reduction, minimal trade-offs In controlled WLTP (Worldwide Harmonised Light Vehicle Test Procedure) tests, Brembo says Greentell rotors reduced particle emissions by 90% compared to uncoated cast-iron rotors. Surface wear was also slashed by 80%, though because the discs themselves are thinner, overall lifespan gains are closer to 20–30%. To make the most of this new disc surface, Brembo also had to develop a new brake pad material, specially designed to work with the smoother coating. Brembo Greentell brakes — Source: Brembo Even wear indicators get a high-tech twist Thanks to the reduced wear rate, traditional disc wear measurements don't quite cut it. Instead, Brembo now etches its logo (or an automaker's logo) onto the disc face. When the logo disappears, it's time to swap the rotors. The idea originates directly from motorsport, where visual wear indicators are already widely used. Autoblog Newsletter Autoblog brings you car news; expert reviews and exciting pictures and video. Research and compare vehicles, too. Sign up or sign in with Google Facebook Microsoft Apple By signing up I agree to the Terms of Use and acknowledge that I have read the Privacy Policy . You may unsubscribe from email communication at anytime. No slots or holes needed 2025 Subaru WRX tS — Source: Elijah Nicholson-Messmer Don't expect flashy drilled or slotted rotors here, though. Those were originally used to combat 'gassing out,' an issue with older pad materials that's largely been solved by modern materials. Plus, those slots and holes increase abrasive wear, exactly what Greentell aims to avoid. Final thoughts Greentell rotors are primarily aimed at helping European automakers comply with Euro 7 and are expected to appear first on premium and performance vehicles — the kind Brembo typically supplies. The U.S. currently lacks similar brake dust regulations, but if that changes, these high-tech rotors could make their way stateside. For aftermarket buyers, Brembo also offers a similar dust-reducing option called Greenance. Both systems represent the growing realization that cutting vehicle emissions isn't just about what comes out of the tailpipe; it's also about what comes off the wheels. About the Author Elijah Nicholson-Messmer View Profile
Motor 1
27-05-2025
- Automotive
- Motor 1
Brake Dust Is a Problem. Brembo Has a Solution
Picture the way brake dust turns your shiny silver wheels into a dull, gray mess. Now imagine what it does for your lungs. When we talk about automotive emissions, we're typically not thinking about brakes. The European Commission is, though, and in the Euro 7 standards set to come into effect next year, there are limits on particulate emissions from brakes. According to a 2023 Automotive Engineering article , the limit for Euro 7's introduction is set at 7 mg/kilometer, and in 2035, the limit will reduce to 3 mg/km. Euro 7 will allow electrified vehicles to have higher brake-emission levels, depending on the type of powertrain, operating under the assumption that motor-regenerative braking means less use of the friction brakes. Regardless, there's a real need to cut brake dust. Brembo's approach is called Greentell, a portmanteau of "green" and "intelligent." Maybe not the most elegant name, but a neat piece of technology. "When Euro 7 will be applied in Europe, the legislation will impact all passenger vehicles or most of them," says Fabiano Carminati, Brembo's head of brake-disc development, in an interview with Motor1 . "So this is the reason why we needed to find a solution from a technological point of view that can be useful for huge volumes, not just a few thousand pieces per year." A generic example of Laser Metal Depositon. That solution revolves around Laser Metal Deposition (LMD), a relatively new form of additive manufacturing where powdered metals are heated by a laser and sprayed on a metallic surface. Without getting too in the weeds, think of it as printing metal. Brembo uses LMD to coat the surface of its brake discs with a proprietary—secret—alloy. Carminati tells us Brembo applies this dual-layer coating after the machining process, and before the final finishing. The results, according to Brembo, are fairly astonishing. On the Worldwide Harmonised Light Vehicles Test Procedure (WLTP) for braking, Brembo claims a 90-percent reduction in particle emissions from its Greentell system. Carminati also says the LMD process only adds minimal time to the manufacturing process. Brembo also says that the LMD coating reduces disc surface wear by about 80 percent compared to an uncoated cast-iron disc. But Carminatti is quick to stress that this doesn't translate directly into an 80-percent increase in disc life, because Greentell discs are actually thinner than traditional cast-iron units. He says Greentell discs should last about 20 to 30 percent longer than their cast-iron equivalents. The new disc coating also required Brembo to develop a new pad material. 'The coupling between the discs and pads is completely different than in a standard cast-iron material,' Carminatti says. Also, because of the relative lack of surface wear, Brembo created a new indication marker for disc life—its logo, etched into the surface. Brembo can replace this with the logo of an automaker, too, but regardless, when the visible logo is gone, it's time to replace your discs. A neat detail, which comes from racing. In the cast-iron brakes you see on GT cars, Brembo debosses its logo into the disc surface as a wear indicator. Carminatti tells Motor1 that, beyond reducing emissions, the overall goal with Greentell wasn't necessarily to improve braking performance, but to provide the same level of stopping power while ensuring consistency in all conditions. LMD provided the best solution without the risk of the coating becoming delaminated from the disc in cold and/or salty conditions. Photo by: Brembo Slotted and drilled rotors have long been associated with high-performance cars, but you won't see a Greentell disc with such cuts or holes. Slotted and drilled rotors were originally designed to prevent 'gassing-out,' a phenomenon where worn-off pad material creates a boundary layer between the pad and rotor surface, significantly reducing braking performance. But they create a more abrasive surface, which increases particle emissions from the disc. Which would negate the entire point of this exercise. Not that you should worry about cooling or stopping power with these plain-surface discs. We've come a long way with material science since drilled and slotted discs first arrived, so gassing out isn't really a concern these days. Holes and slots are mostly present these days for weight savings, cooling, or to get a bit more bite from the pads. Since these brakes are designed to help automakers meet Euro 7 emissions, Brembo says it's mainly targeting the European market, though they could come to the US eventually if an automaker wants them. (We don't have any rules about particle emissions from brakes here, though we do have regulations on certain materials used in braking systems.) And Brembo being Brembo, Greentell is targeted mostly at premium and performance cars, its typical market. For aftermarket customers, Brembo also offers a similar product, Greenance, which targets similar emissions reductions. This is, ultimately, a small piece of a very complex puzzle. Automakers and suppliers all have to be clever in how they meet the aggressive Euro 7 emissions, and it'll take more than just electrifying powertrains. More Engineering Deep Dives Giamaro's Quad-Turbo V-12 Is Insane: 'The King of Engines' How Oil Analysis Reveals Your Engine's Secrets Get the best news, reviews, columns, and more delivered straight to your inbox, daily. back Sign up For more information, read our Privacy Policy and Terms of Use . Share this Story Facebook X LinkedIn Flipboard Reddit WhatsApp E-Mail Got a tip for us? 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