A complete & optimized braking performance
Explore what makes our braking solutions great
Every Kovis part starts as a material decision. Grain structure, thermal stability and how a metal behaves under real braking heat.
The material is where the difference is made - a difference between a disc that performs and one that just meets tolerance.
to intelligent braking
KOVIS Friction Excellence is our commitment to engineering complete braking performance through the perfect integration of materials, friction interfaces, manufacturing excellence, intelligent technologies and life cycle optimisation.
We engineer braking performance.
High technical requirements and detailed components specifications often exceed what standard ductile or grey iron can achieve.
In our in-house laboratory we develop and test new alloys that push the boundaries of speed, heat resistance and lifetime cycle.
SiNiMo cast iron
CuMo cast iron
For demanding thermo-mechanical applications where conventional ductile and compacted graphite irons reach their limits.
Ideal for high speed train brake discs.
- Patented alloy
- Ferritic matrix, vermicular graphite
- High strength with good thermal conductivity
- High resistance to thermal fatigue
- Exceptional as-cast strength
- No heat treatment required
- Good wear resistance
- High strength retention at elevated temperatures up to 400°C
Patented high-silicon vermicular cast iron with a predominantly ferritic matrix.
Excellent thermal shock resistance up to 500°C, enabled by a favourable balance of mechanical strength and thermal conductivity.
Successfully passed brake bench testing on an axle-mounted railway brake disc for D1 category / speeds up to 250 km/h.
Outstanding thermal fatigue resistance: up to 265 % more cycles to failure compared with standard EN-GJS-500-7.
High-strength pearlitic ductile iron bridging the gap between conventional ductile iron and cast steel, while retaining the manufacturing advantages of casting.
Good wear resistance, confirmed by brake disc and pad wear measurements during bench testing.
Successfully passed test bench on axle mounted brake disc for D1 category – up to 250 km/h.
Mechanical properties
As-cast specification
 Property |  t ≤ 30 mm | 30 < t ≤ 60 mm |
|---|---|---|
 Yield strength, Rp0.2 | ≥ 480 MPa | ≥ 460 MPa |
 Tensile strength, Rm | ≥ 550 MPa | ≥ 520 MPa |
 Elongation, A | ≥ 3 % | ≥ 3 % |
Mechanical properties
As-cast specification
| Property | t ≤ 30 mm | 30 < t ≤ 60 mm |
|---|---|---|
| Yield strength, Rp0.2 | ≥ 580 MPa | ≥ 520 MPa |
| Tensile strength, Rm | ≥ 850 MPa | ≥ 800 MPa |
| Elongation, A | ≥ 4 % | ≥ 3 % |
As-cast
No heat treatment required
Every new material is thoroughly screened and validated in our own NDT/DT laboratory.
- Chemical analysis (Thermical analysis, Spectrometer analysis)
- Metallographic analysis (Microstructure, grain sizes)
- Carrying out VT, PT and UT tests
- Optional: MT tests (external)
- 3D scanning of casting – reverse engineering
- 3D and 2D measurements of casting
- Digital Radioscopy
- Mechanical analysis (tensile test 250 Kn)
- Charpy – impact stress test (room temperature, temperature from +20°C to -40°C)
Hercules, a Miba certified machine for dynotesting ... ????
Every braking event is the result of two components working as one.
Why SMART?
Sustainable engineering
Material excellence
Advanced Friction Technology
Reliable Performance
Technology Intelligence
The interaction between the brake disc and brake pad determines braking efficiency, thermal behaviour, wear characteristics and operational reliability.
Through continuous material development, extensive testing and application engineering, we optimize every friction pair to deliver:
- consistent braking performance
- reduced wear
- longer component lifetime
- lower maintenance costs
- predictable performance under all conditions
Application:
- Intercity & regional trains
- Suitable for Class C2 (UIC 541-3, EN14535-3)
- Speeds up to 250 km/h
Customer benefits:
- Lower operating temperatures
- Reduced coning and thermal deformation
- Lower ventilation losses
- Longer component lifetime
- Lower maintenance costs
- Full interchangeability
Application:
- Freight & regional trains
- Suitable for EN 14535 Class C2
- Speeds up to 250 km/h
Customer benefits:
- Lower operating temperatures
- Reduced coning and thermal deformation
- Lower ventilation losses
- Full interchangeability
- Extended service life
- Lower maintenance costs
Brake disc and pad engineered to fit seamlessly together.
Tested and approved with high scores across the board.
vs. KNORR BREMSE
- ???
- 28 tests, 12 weeks
- 7 disc materials
- 4 friction materials
sMart braKe Screening
Test matrix
Total Number of Tests
28
Duration
12 weeks
Lorem ipsum image description Company made for (Siemens Germany)
sMart braKe Screening
Selected Test Results
(Extracts from the evaluation tool)
Lorem ipsum image description Company made for (Siemens Germany)
sMart braKe Screening
Selected Test Results - Further Details
(Extracts from the evaluation tool)
Lorem ipsum image description Company made for (Siemens Germany)
Behind every part we produce stands a group built around one idea: complete integrated solutions for safer, more efficient and climate-friendly rail transport and beyond.
Kovis Group operates five production sites across four countries.
Each with a focused role, all working as one.
Kovis Group at a glance
20x
increased sales turnover in the last 10 years
5
productions sites
43
countries sales
20x
increased sales turnover in the last 10 years
We are an independent / family-owned company.
We create good & innovative ideas for the future.
We are a trustful & reliable partner.
Highest quality in all our operations & processes.
Our encouraged employees are a key factor in our success.
Green mobility & sustainability is our path.
Kovis USA
kovis bp
JWL Kovis India
From castings to finished and tested parts.
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Sustainability runs through how we think, develop and work. It is not just a word written in our documents. It is in our material sourcing, energy use, and what happens to scrap.
90%
recycled
raw materials
24 %
electricity from
own solar plant
Circular economy
scrap reused
in next melt
45+ years
of innovation and reliability
- ISO 9001 Quality Management (Kovis, Kovis BP, Kovis Livarna)
- ISO 14001 Environmental Standard (Kovis, Kovis Livarna)
- ISO/TS 22163:2023 (Kovis, Kovis BP)
- EN 15085-2 (Kovis)
- ISO 45001 Occupational Health & Safety (Kovis Livarna)
- ISO 50001 Energy Management (Kovis Livarna)
- HPQ DB (Deutsche Bahn High-Performance Qualification)
Lorem ipsum image description
Company made for (Siemens Germany)
By combining innovative cooling concepts, reduced mass and optimised design, our products deliver higher thermal efficiency, lower ventilation losses and extended service life.
These innovations contribute to:
- lower energy consumption and CO₂ emissions
- reduced maintenance and life-cycle costs
- and improved braking performance and reliability
Patented XNET cooling design brings high stiffness, lower friction-surface stresses and optimal air recirculation within the pockets for enhanced heat dissipation.
Special Grey Cast iron
SiNiMo
High Strength Steel
- 50–60 % lower ventilation power losses:
lower energy consumption and CO₂ emissions - Energy efficient:
savings in energy and CO₂ emissions - Lower operating temperatures compared with state-of-the-art brake discs: reduced thermal stress in the disc
- Less conical deformation, less wobble
- Reduced component mass
- Interchangeability:
available in 8-hole and 12-hole wheel design - Suitable for all energy classes:
acc. to UIC 541-3, EN 15328, EN 14535-3
FSO brake discs bring greater efficiency through better heat dissipation, lower mass and lower ventilation losses. They enable shorter braking distance and higher safety due to special patented brake plate-hub connection.
590/170 mm
590/110 mm
with sinter pads
- 22.7 % lower mass for 170 mm disc / 34.5 % for 110 mm disc
- 21 % lower ventilation losses for 170 mm disc / 34 % for 110 mm disc
- 17.3 % higher thermal dissipation efficiency for 170 mm disc / 32.7 % for 110 mm disc
- 18 % longer service life
- 60 % lower maintenance cost due to divided version (mounting)
- 20 % Lower LCC
- Energy efficient: savings in energy and CO₂ emissions
By combining KOVIS brake disc expertise with in-depth knowledge of Sintered and Organic friction materials, we engineer the friction pair as one integrated system – delivering the right balance of performance, durability and life-cycle value.
- Complete friction-pair expertise: brake disc and brake pad considered as one system
- Sintered & Organic know-how: the right friction technology for each application
- Optimised performance: stable friction behaviour across different operating conditions
- Balanced wear: optimising both disc and pad lifetime
- Application-specific solutions: tailored to vehicle, duty cycle and operating environment
- Lower Life Cycle Cost: performance measured beyond the component price
- High thermal resistance: stable braking performance even under extreme temperatures and repeated braking cycles
- Consistent friction performance: predictable coefficient of friction across a wide operating range
- High braking capacity: particularly suitable for demanding, high-energy applications
- Excellent wear resistance: longer pad life under intensive operating conditions
- Robust in challenging environments: reliable performance in wet, cold and changing operating conditions
- High mechanical strength: designed to withstand high loads, pressures and thermal stresses
| Project (Nr) | Status | Application | Max Speed (km/h) |
Disc Material | Disc Life Improvement (%) | Pad Design | Pad Material | Pads Life Improvement (%) | Hollow Wear Reduction | Noise Reduction |
|---|---|---|---|---|---|---|---|---|---|---|
| 1 | Delivery in place | HS Platform | 250 | Steel | 55 | FLEX PAD | MD 601 | 40 | – | – |
| 2 | Test Completed | DD EMU | 160 | Steel | 10 | FIXSTAR | MD 610 | 20 | ✓ | ✓ |
| 3 | Test in progress | VHS Platform | 350 | Steel | TBD | FLEXSTAR | MD 615 | TBD | – | – |
| 4 | Test in progress | EMU | 160 | Steel | – | FIXSTAR | MD 610 | 39.3 | – | ✓ |
| 5 | Test in progress | Coaches | 200 | Steel | 80 | FIXSTAR | MD 610 | – | ✓ | – |
| 6 | Test in progress | VHS platform | 300 | Steel | TBD | FLEXSTAR | MD 616 | TBD | – | – |
| 7 | Test in progress | Freight | 140 | Cast Iron | TBD | FIXSTAR | MD 620 | TBD | – | – |
Miba is actively working in the railway market and the results are starting to produce feedback, confirming the forecast made during the preliminary projects evaluations.
The Miba FixStar brake pad is designed for medium speed applications up to 200 km/h, with improved material composition (e.g. MD610) and design for optimized NVH characteristics and Life Cycle Costs.
Features
- Rigid brake pad solution
- Tailor made brake pad (e.g. dovetail position)
- Improved material composition for optimized NVH behavior
UIC Homologation finished for passenger trains with MD610 up to 200 km/h, energy class 11.8 MJ
The Miba FlexStar brake pad is designed for high-speed applications up to 400 km/h, with improved design for optimized NVH characteristics, hot spot reduction and low counter-wear.
Features
- flexible brake pad solution
- Adjustable friction material
- Lower NVH emissions & hot spot reduction
MIBA is our development partner in the Smart Brake segment, providing elevated brake pads that fit seamlessly our brake discs. Brake and pad are tested and approved together.
The Group’s key elements boost the efficiency and performance of clutches and brakes for vehicles and industrial applications.
- 1529 Employees
- 7 Friction Sites Worldwide
- Own R&D and Test Center
- Low-to-medium thermal loads, passenger trains, subways, light rail, and regional trains
- Low Noise & Vibration: Softer than sintered alternatives; quieter operation, minimal squeal
- Low Disc Wear: Gentler on cast iron or steel discs, extending overall disc service life
- Stable Friction Coefficient: Smooth, consistent braking across a wide temperature range
- Thermal Insulation: Lower conductivity than sintered metal pads, reducing heat transfer to calipers/holders
- Environmental & Safety Compliance: Asbestos-free, lead-free, EU REACH-compliant
- Material Composition: Resin-bonded synthetic fibres, organic modifiers, rubber, and mineral fillers
Kovis brake discs seamlessly integrate with all organic brake pad types and sizes.
- Standard UIC-compliant shape, two segmented friction blocks
- Standardized area specified by UIC leaflet guidelines for general international railway interchange
- Cross-slots and gaps between blocks allow heat dissipation and gas clearance
- Segmented design prevents uneven pressure, reducing local hot spotting
- Standard safety factor; widely used as a benchmark for international rolling stock
- Single-piece (monoblock) design with a continuous, elongated friction surface (“long tongue” geometry)
- Gaps between the two pads allow thermal expansion and air flow, but localized peak temperatures can be slightly higher than SFZ
- Concentrates pressure over two distinct pad zones
- Slightly higher internal thermal stresses under emergency braking compared to SFZ
- Two-piece pad design consisting of two separate pads mounted side-by-side on a common holder
- Superior heat distribution: continuous contact reduces peak surface temperatures and thermal gradients
- Distributes contact pressure more evenly across the entire disc track
- Lowest internal stress levels and highest safety factor under high thermal loads (e.g., emergency braking)
for every application
Brake discs are our core. And what we are most known for.
At Kovis we engineer a variety of brake discs matched to speed, load and vehicle type. We are here to advise you and help you find the optimal solution. Because every application is specific, we can customize to your design or specimen.
550+
disc types in production
95 %
recycled content
125+
rail customers
45+ years
of innovation and reliability
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Company made for (Siemens Germany)
Every passenger vehicle brakes differently, so the mounting type is the first engineering decision everything else follows from.
At Kovis, we advise, engineer and produce your chosen brake disc matching the most suitable connection system, material and cooling design.
Variants: non-divided, divided, monoblock
Connection system:
bolt (type K), bush (type P), monoblock (type N), shape (FSO)
Design can be adjusted to customer needs.
Variants: non-divided, divided
Connection system:
bolt+bush (type G), bolt (type K)
Design can be adjusted to customer needs.
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Vstavi GLB!
Variants: non-divided,
Design can be adjusted to customer needs.
Freight wagons are specific, as they carry loads passenger trains never will. At Kovis, we optimize freight brake discs for load and longevity, choosing the right material and application for specific undercarriage designs.
for freight wagons
Connection and cooling system variants:
- bolt (type K) + TSK
- shape + FUTURA FSO
- bolt (type K) + QSK
Design can be adjusted to customer needs.
