Brake System Materials Upgrade Report

I’m putting together a concise engineering report that recommends new, cost-effective materials for an everyday passenger-car braking system. The scope is limited to four components—brake pads, brake discs, calipers and the brake pedal—and my priority is to find options that can be mass-produced cheaply while boosting resistance to wear and corrosion. Your tasks • For each component, select one promising alternative material, then outline a realistic, scalable manufacturing route that fits high-volume automotive production (e.g., powder metallurgy, low-pressure casting, injection moulding, additive manufacturing where justified). • Use Ansys Granta to generate comparative charts that clearly show the proposed material outperforming today’s conventional choices in wear rate, corrosion loss, and any cost or throughput metrics that reinforce the “lower cost + easy mass production” goal. • Back every recommendation with brief, data-driven reasoning—thermal limits, mechanical strength, machinability, supplier availability, recyclability, etc.—but keep the report streamlined and visually led. Figures and tables should speak for themselves. Deliverables 1. PDF report (≈8–10 pages) covering: – Material selection rationale for each component – Manufacturing process overview and indicative production steps – Side-by-side property tables and Granta charts (editable originals also supplied) – A short conclusion comparing overall lifecycle cost to current materials. 2. Native Ansys Granta project file(s) containing the chart setups. 3. Any calculation spreadsheets or scripts used for supporting metrics. Acceptance criteria • All charts generated directly from Ansys Granta with labels and legends intact. • Evidence focuses on wear & corrosion resistance and unit-cost drivers. • Recommendations remain feasible for an everyday passenger car, not niche motorsport. • Text is original, clearly referenced, and free of jargon overload. If you’re confident working with Ansys Granta and automotive manufacturing methods, I’d love to see a brief outline of how you’d tackle the four components and what data sources you’d lean on.