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1. INTRODUCTION
Operators often ask how to increase the life of carbon brakes, because the brake life obtained may be
less than expected. Two different factors affect the life of carbon brakes:
- The wear of the discs (refer to Chapter 2),
- The oxidation of the discs (refer to Chapter 3).
This article also develops best practices for operating the carbon brakes (refer to chapter 4).
Carbon wear is a very complex process. There are also different types of carbon, and each type wears
in a different manner.
The two main factors that affect the wear of carbon brakes are
- The number of brake applications,
- The temperature of the carbon discs at which the brakes are operated.
Note: The wear spectrum from UTAS displays the combined results from dynamometer simulation
(above 80-100 °C) and theory (below 80-100 °C). Wear rates below 100 °C are reduced, due to
lubrication by the atmospheric moisture that adheres to the carbon particles. Above 100 °C, wear rates
reduce as the temperature increases.
The energy absorbed by the brakes (e.g. at landing) does not significantly affect the wear of the
carbon brakes (unlike it is the case on the steel brakes).
However, the application of more energy on the brake has an effect on carbon brake wear, as it
causes an increase in brake temperature.
Brakes may degrade rapidly due to carbon oxidation. Oxidation may also cause the rupture of a disc.
Two types of oxidation may affect carbon:
- Catalytic Oxidation: Mainly due to runway and aircraft de/anti-icing fluids and other cleaning
agents
- Thermal Oxidation: That is accelerated at high temperatures. Therefore, if the brakes absorb too
much heat, carbon oxidation increases.
However, there is no difference between the effects of Thermal or Catalytic oxidation. The potassium
or sodium present in de/anti-icing fluids acting as a catalyst further accelerates the oxidation. It should
be understood that once the potassium or sodium is absorbed by the carbon it does not simply go
away. Catalytic oxidation can continue after the winter has finished based on the damage caused by
absorbed alkalis.
The table below indicates the time required at different temperatures, to lose 5 % of the carbon mass
(or 25 % of the mechanical strength).
All recommended braking techniques should mainly aim at reducing the number of brake applications
and at optimizing the carbon brake temperature.
In order to reduce the number of brake applications, consider the following techniques:
• For most brake types, the taxi-in temperature is to the right of the wear-curve peak given in Figure 1,
due to heat build-up during landing. Therefore, it is not recommended to cool the brakes after
landing, as this would make it necessary to operate in the high-wear range, in order to move to the
left of the wear curve.
700
Taxi in
600 Disk
temperature
Temperature (°C)
500
landing Indicated
Taxi out
temperature
400
300
200
parking
100
1st flight 2nd flight 3rd flight
0
0 50 100 150 200 250 300 350 400
However, it is not easy to manage brake temperature. The best solution is to use the brake cooling
fans, if available.
Note: Brake temperature may be further difficult to manage because, in normal operations, there may
be a significant difference between the temperatures of the different wheel brakes. The brake
temperature of some wheels may be on one side of the peak of the wear curve, some may be
on the other side, and some may be on the peak.
The FCOM and the TSM list the brake temperature limitations that require maintenance actions.
For example:
- The temperature difference between the two brakes on the same gear is more than 150 °C,
and the temperature of either one of the brakes is more than or equal to 600 °C, or
- The temperature difference between the two brakes on the same gear is more than 150 °C,
and the temperature of one brake is less than or equal to 60 °C, or
- The difference between the average temperatures of the LH and RH brakes is more than or
equal to 200 °C.
It is difficult to provide accurate and detailed recommendations on the operation of carbon brakes, that
take into account both safety and economy and are applicable to all customers and all brake types.
All brake manufacturers also highlight the importance of customized brake-saving recommendations
for each Operator. The environment, the conditions, and the fact that the aircraft may or may not have
brake fans, significantly affect how the flight crew should operate the brakes.
The following are general Airbus recommendations on the correct operation of carbon brakes.
These recommendations list all the systems involved in brake operation:
• Taxi Out
If an arc appears on the ECAM WHEEL page, above the brake temperature (with a brake temperature
> 100 °C), select brake fans ON. This will ensure:
- A maximum energy rejected takeoff will be sustained
- An acceptable brake temperature for taxi, in terms of brake wear.
• Before Takeoff
If the brake fans are running, check that the brake temperature is below 150 °C (except for some
brake types - see General Remarks above). If the brake temperature is above 150 °C, delay takeoff
until the temperature decreases to 150 °C with the fans running, then switch the fans OFF.
• Taxi In
Airbus recommendations are based on the advantages (described by all brake manufacturers) of a
taxi with hot brakes, but also take into account the possibility of oxidation.
Delay selection of the brake fans for at least 5 minutes, or until arrival at the gate (whichever occurs
first), to enable thermal stabilization, and avoid the oxidation of hot spots on the brake surfaces (*).
(Select the brake fans just before arrival at the gate, in order to avoid blowing carbon dust on the
ground crew.)
However, when turnaround times are short, or brake temperatures will probably exceed 500 °C, use
the brake fans (disregard oxidation) to avoid a possible melting of the wheel fuse plugs.
For taxi in, disregard the arc on the ECAM WHEEL page. Also, the display of the BRAKE HOT
warning and/or light on the ECAM (on some aircraft) should not result in the immediate selection of the
brake fans; provided that the brakes will probably not reach 500 °C (wait 5 minutes or until arrival at
the gate).
(*) Some brake manufacturers consider that the recommendation to delay the selection of brake fans
5 minutes after landing has not proved to efficiently prevent brake oxidation. Indeed this possible
gain may be offset by the fact that the carbon stays longer at a higher temperature when no using
the brake fans immediately after landing (Refer to figure 2).
• Parking
Select fans OFF if no arc appears on the ECAM WHEEL page (temperature < 100 °C). If the
turnaround is short, keep the fans running until the brake temperature is almost the same as the
ambient temperature.
5. CONCLUSION
Airbus liaises constantly with brake manufacturers, in order to provide the best recommendations on
the correct operation of carbon brakes. All parties agree that, in terms of brake life, it is important to
customize the recommendations, to take into account the specifics of each Operator. Remember also
that not all brake manufacturer recommendations are exactly the same, due to the different types of
carbon used. However it is vital that any airline policy does not deviate from Airbus published
procedures and limitations.
© Airbus SAS, 2016. All rights reserved. Confidential and proprietary document.The technical information
provided in this article is for convenience and information purposes only. It shall in no case replace the
official Airbus technical or Flight Operations data which shall remain the sole basis for aircraft
maintenance and operation. These recommendations and information do not constitute a contractual
commitment, warranty or guarantee whatsoever. They shall not supersede the Airbus technical nor
operational documentation; should any deviation appear between this article and the Airbus or airline's
official manuals, the operator must ensure to cover it with the appropriate document such as TA, FCD,
RAS. Access to WISE is supplied by Airbus under the express condition that Airbus hereby disclaims any
and all liability for the use made by the user of the information contained in WISE. It shall be used for
the user's own purposes only and shall not be reproduced or disclosed to any third party without the
prior consent of Airbus.