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Rotors do not warp as many people think.Brake Torque Variation and Disc Thickness Variation are the cause of the issue.

Brake Torque Variation (BTV) is a variation of torque across the face of the rotor causing the rotor to slip and catch as brake pads pinch the rotor. The differences in torque across the rotor may be caused by an inconsistent rotor finish or the Metallurgy of the rotor.BTV can be caused by uneven deposits of friction material. This might not cause a pulsation in the pedal, but it will cause the vehicle to judder or vibrate.

Disc Thickness Variation (DTV). This measurement is the result of measuring the thickness of the rotor surface at multiple spots around the rotor. Subtract the thickest part from the thinnest, and you will have a measurement for DTV.

As the thickness variations of the rotor pass through the caliper, the piston moves in and out. This action generates pulsations in the brake pedal that can be felt by the driver.

Very small amounts of DTV can create a significant problem. Today, new vehicles are typically built with a thickness variation of less than 0.00078". Thickness variations in excess of 15 microns (0.00059") can easily generate driver complaints. DTV specifications are significantly lower than runout specifications which typically are .002". This is due to the fact that a caliper can "float" or move back and fourth without forcing the piston back into the bore.

So what causes BTV and DTV? The answer is not distortion caused by overheating. Heat does play a role as it increases wear on the rotor that causes a "warped" feeling.

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