Jekit car 9040 custom color caliper with 355x32 iron disc for A5

Casting or forging?
The brake caliper body is usually made by casting and forging processes. In short, the mechanical strength of the caliper body with forging process is higher than that of casting, and the product price of casting process is relatively low, which has a great relationship with the manufacturing cost.
The production of casting caliper body is assisted by the mold. The aluminum ingot is melted and poured into the mold to be solidified and formed. Finally, the metal burr, seam and other substances are removed to complete the production of a caliper body. A shape mold can realize the possibility of mass production. (note that the interior of the cast caliper also needs CNC processing, and whether it is cast or not cannot be argued based on whether there is a knife path).
Forging calipers uses aluminum alloy as the raw material, uses high-pressure punching to forge the basic shape of calipers, and then uses CNC machining technology for cutting. The material structure is more compact, and the heat dissipation performance and material rigidity will be much stronger than those of casting materials.
Forged calipers have excellent performance and can be produced in small quantities for different models. In Taiwan and European and American markets, basically, the refitting is mainly forging. The cast calipers are also cost-effective, which is enough for daily street use.
A good caliper structure design needs accurate calculation. The piston hole should be designed for exhaust and processed with special tools and equipment. The accuracy requirements are very high and the processing time is long.
Balance between appearance and performance
The surface treatment of the modified caliper body is mostly based on ordinary anode, and hard oxidation will be used for high-end performance calipers.
1. Common anode
Ordinary anodizing refers to the process that aluminum and its alloys form an oxide film on aluminum products (anodes) under the action of external current under the corresponding electrolyte and specific process conditions.
The advantage of ordinary anode is that it is cheap and has certain anti-corrosion function, so it has high cost performance. The disadvantage is that the hardness is relatively low, and the treatment layer is very thin, resulting in easy scratches (scratches will occur when the key is gently scratched), and the protective effect will be lost after scratches.
2. Hard anodizing
Sparta's caliper products do not use ordinary anodes, but use hard anodized surface treatment instead.
The principle of the so-called hard oxygen is similar to that of Puyang, but the use of raw materials and processing methods are different, which greatly enhances the surface wear resistance. After hard oxidation of aluminum alloy, the surface hardness can reach about HV500 and the thickness is 25-250um. Strong adhesion, 50% of the generated oxide film penetrates into the aluminum alloy and 50% adheres to the surface of the aluminum alloy.
Among the mainstream processes, hard oxygen has the best wear resistance and is widely used in military and other fields. It is the most suitable surface treatment process for high-end functional caliper products.