Method for coating a brake disc made of grey cast iron or steel

Abstract

The invention relates to a method for coating a brake disc (1) made of gray cast iron or steel, wherein the brake disc (1) has a base body and at least one disc-like body (11) extending radially therefrom perpendicular to an axis of rotation (D) of the brake disc (1), the disc-like body having a surface (11a) whose surface normal is parallel to the axis of rotation (D). The disc-like body (11) defines an outer diameter (d1) of the brake disc (1), wherein the outer diameter (d1) has a radially external interference (Ü1) compared to a nominal outer diameter (d2).A coating (B) is applied to the surface (11a) of the disk-like body (11) by means of a tool (13) in laser cladding. The coating consists of a first layer (B1) of stainless steel applied to the surface (11a) of the disk-like body (11) and at least one second layer (B2) applied to the first layer (B1), which is a composite of an iron alloy matrix with embedded hard particles. According to the invention, it is proposed that the coating (B) is carried out without a prior machining operation by which the outer diameter (d1) of the brake disc (1) is reduced to the target outer diameter (d2).

Description

[0001] The invention relates to a method for coating a brake disc made of grey cast iron or steel with the features of the preamble of claim 1.

[0002] The coating of brake discs is intended to significantly reduce particulate matter emissions generated during braking of motor vehicles, thereby minimizing environmental impact. Current trials involve manufacturing such brake discs by first turning delivered brake disc blanks to a predetermined finished or nominal diameter. The surface(s) of the disc-like body are then coated. This involves first applying a layer of stainless steel, which is then coated with a layer of a composite iron alloy matrix containing embedded hard particles. Both layers are applied to the respective substrate using laser cladding.

[0003] During the coating process, the tool, which directs both the coating material and the laser beam onto the substrate to be coated, is moved radially across the substrate. Moving the tool radially from the inside out, it will advance to the outer diameter of the brake disc when applying the first layer. The second layer is applied in the same way, by moving the tool to the outer diameter of the brake disc.

[0004] Tests have shown that this method causes heat to build up in the edge area of ​​the brake disc. This is associated with a significant local temperature increase, which leads to a reduction in the coating quality in the edge area.

[0005] A method for manufacturing a brake disc for a vehicle is known from US Patent 10,274,032 B2. The method first involves heating the brake disc and then immersing it in a molten metal alloy, such as an aluminum or zinc alloy. The metal layer applied to the entire brake disc acts as both an adhesion promoter and a corrosion inhibitor. The brake disc is then machined to the required dimensions. Finally, a hard metal powder, which may contain tungsten or titanium carbide, is applied to the friction surfaces of the brake disc by high-speed flame spraying.

[0006] DE 10 2023 204 087 B3 relates to a brake caliper for a motor vehicle, comprising a base body that is at least partially planar, on whose surface surfaces at least two superstructure layers are applied, at least partially. These superstructure layers form a surface that, when the brake caliper is mounted on the motor vehicle, serves as a friction surface for a brake pad. A bonding zone exists in which both a material from the base body and a material from an adjacent superstructure layer are present. The second superstructure layer consists of a composite of an iron alloy matrix with embedded tungsten carbide particles.

[0007] DE 10 2023 136 849 A1 discloses a brake disc for a wheel of a motor vehicle, comprising: - at least one friction surface; - a connecting section for torque-resistant connection to a wheel hub. The brake disc is characterized in particular by the fact that the friction surface has a predetermined surface roughness of less than 6 µm. With the surface roughness of the friction surface of the brake disc proposed here, good braking performance over a long service life and at the same time very low particulate matter emissions can be achieved.

[0008] German patent DE 10 2023 114 366 A1 describes a method for generating control data for 3D printing. Different areas of a component are specifically analyzed and individually controlled to optimize material properties. For example, particularly stressed zones can be made more stable or thermally conductive. The goal is more efficient and higher-quality additive manufacturing.

[0009] The present invention is based on the objective of proposing a method for coating a brake disc made of grey cast iron or steel, with which an improvement in the coating quality of the brake disc can be achieved.

[0010] This problem is solved by a method with the features of claim 1. Advantageous embodiments or further developments of the invention can be found in the dependent claims.

[0011] The invention relates to a method for coating a brake disc made of gray cast iron or steel. The brake disc to be coated has a base body and at least one disc-like body extending radially from it perpendicular to an axis of rotation of the brake disc, with a surface whose surface normal is parallel to the axis of rotation. The disc-like body defines an outer diameter of the brake disc. This outer diameter has a radially external interference compared to a nominal outer diameter. A coating is applied to the surface of the disc-like body by a tool using laser cladding. The coating consists of a first layer of stainless steel applied to the surface of the disc-like body and at least one second layer applied to the first layer, which is a composite of an iron alloy matrix with embedded hard particles.The second layer later provides a friction surface for the brake pads to adhere to when the brake disc is mounted on the vehicle.

[0012] The stainless steel can preferably be an austenitic or ferritic stainless steel. For example, it is conceivable that the first layer consists of an austenitic chromium-nickel-molybdenum steel, which exhibits material properties corresponding to material 1.4404 according to standard EN 10027-2 or material 316L according to standard AISI. Depending on the material properties of the brake disc, however, it is alternatively conceivable and has proven advantageous if the first layer consists of a ferritic stainless steel, which exhibits material properties corresponding to material 1.4016 according to standard DIN EN 10027-2 or material 430L according to standard AISI.

[0013] The second layer comprises an iron alloy matrix, which also preferably consists of the aforementioned materials 316L or 430L. The hard particles may preferably consist of an alloy of titanium carbide and ferrochrome (TiC-FeCr) or of titanium carbide or tungsten carbide alone.

[0014] The invention now proposes that the coating is carried out without a prior machining process by which the outer diameter of the brake disc is reduced to the target outer diameter.

[0015] Prior machining of the brake disc, including machining of the outer diameter, is not fundamentally excluded, as long as the machining process does not reduce the outer diameter of the brake disc to the target outer diameter.

[0016] This method creates the conditions for a noticeable improvement in the coating quality of the brake disc, particularly in its outer edge area. The coating is not terminated at the outer edge, thus preventing significant heat build-up and local temperature increases in that area. This, in turn, prevents carburization of the first layer and the occurrence of bonding defects.

[0017] Further development proposes that a brake disc with a radial outer oversize in a range of about 1.5 mm to about 5.0 mm, preferably in a range of about 2.0 to about 3.0 mm and particularly preferably with a radial outer oversize of about 2.5 mm, be used.

[0018] It has been shown that choosing such an excess allows for a very good middle ground between achievable process improvement and material expenditure.

[0019] According to one embodiment of the invention, when applying the coating by laser cladding, the tool is moved radially over the substrate to be coated such that the outer diameter of a laser beam generated by the tool is just adjacent to the outer diameter of the brake disc. In other words, the laser beam or the laser spot generated on the substrate does not extend beyond the outer diameter of the brake disc.

[0020] This prevents the laser beam from uncontrollably entering parts of the coating system at the edge of the brake disc. This also prevents damage to the system from the high-energy laser beam.

[0021] According to another method, the second layer is treated by grinding. The laser cladding process creates a very hard, sooty, and rough surface on the second layer. Such a surface would damage the brake pads during braking. A suitable surface finish can be achieved through grinding, particularly with a diamond-tipped grinding tool.

[0022] Following a highly advantageous machining process, the disc-shaped body is machined by turning, either before or after grinding, thereby reducing its outer diameter to the target outer diameter. Turning the outer diameter to the target dimension always takes place only after the surface of the disc-shaped body has been coated. This achieves several positive effects: • Overspray from the coating process can be removed. Overspray refers to an area of ​​the brake disc located radially adjacent to the coated surface (friction surface). During the application of the second layer by laser cladding, heated hard particles strike this area and adhere to it or melt into it. Removing the overspray improves the subsequent paintability of the surfaces adjacent to the coating with a corrosion inhibitor. • The transition area at the edge of the friction surface (transition from the disc-like body made of gray cast iron or steel to the coating) can additionally be chamfered. This, in turn, has a positive effect on the notch effect. Furthermore, it also facilitates the painting of the transition area with a corrosion inhibitor.

[0023] A further development proposes the use of a brake disc in which the base body is connected to the disc-like body via a trough-like recess. The inner diameter of the disc-like body is provided with a radially internal interference relative to a nominal inner diameter. This interference can be in the range of approximately 1.5 to 5 mm, preferably in the range of 2 to 3 mm.

[0024] This method offers the advantage of noticeably improving the coating quality of the brake disc, even in its inner edge area. In particular, the coating is not terminated at an edge (transition between friction surface and trough-like depression), thus preventing significant heat build-up and local temperature increases.

[0025] To minimize overspray in the area of ​​the trough-like depression during coating application, the coating tool is moved radially across the substrate to be coated during laser cladding until the outer diameter of the generated laser beam is just adjacent to the inner diameter of the disc-shaped body. In other words, the laser beam, or the laser spot it creates on the substrate, does not extend beyond the inner diameter of the disc-shaped body.

[0026] Finally, a further development of the process involves machining the disc-shaped body by turning it before or after grinding, thereby increasing its inner diameter to the target inner diameter. This allows any remaining overspray in the trough-like recess to be removed, which in turn facilitates the application of a corrosion inhibitor.

[0027] It should be noted that during the turning process, the entire trough-like area is advantageously turned out, thereby reducing not only the overspray but also any excess material present in this area to the target dimension.

[0028] A preferred embodiment of the invention is illustrated in the figures and is explained in more detail in the following description with reference to the figures. This will also clarify further features and advantages of the invention. Identical reference numerals, even in different figures, refer to identical, comparable, or functionally equivalent components. Corresponding or comparable properties and advantages are achieved even if no repeated description or reference is made to them. The figures are not, or at least not always, to scale. In some figures, proportions or distances may be exaggerated to more clearly emphasize features of an embodiment.

[0029] They show, schematically, each one Fig. 1 a blank brake disc as used for the process, Fig. 2. A representation of the procedure with a radial movement of the tool from the inside to the outside, until the outer edge of the brake disc is reached. Fig. 3. A representation of the method with a radial movement of the tool from the outside to the inside, up to the inner edge region of the disc-like body of the brake disc and Fig. 4. A representation of a possible processing of the already coated brake disc.

[0030] In Fig. Figure 1 shows the blank of a brake disc 1, which is used as the starting point for the process. The brake disc 1 is made of gray cast iron. It has a hub-like base body 10. A disc-like body 11 extends radially from the base body 10. For reasons of symmetry, only one half of the brake disc 1 is shown, both vertically and horizontally.

[0031] The base body 10 serves to attach the brake disc 1 to a wheel carrier (not shown) of a motor vehicle. The base body 10 is connected to the disc-like body 11 via a trough-like recess 12, which serves as a heat-equalizing groove. The disc-like body 11 has a surface 11a, the normal of which is parallel to an axis of rotation D of the brake disc 1. Since only one half of the brake disc 1 is shown horizontally, there is another surface of the disc-like body 11 opposite surface 11a. The procedure described below also applies to this surface.

[0032] Brake disc 1 has an outer diameter d1. Furthermore, a nominal outer diameter d2 is shown with a dashed line. The blank for brake disc 1 therefore has an oversize Ü1 with respect to the nominal outer diameter.

[0033] Furthermore, the disc-like body 11 has an inner diameter d3. A nominal inner diameter d4 is also shown, indicated by a dashed line. The blank of the brake disc 1 therefore also has an interference Ü2 with respect to the nominal inner diameter of the disc-like body 11.

[0034] The radial outer oversize Ü1 is in the range of approximately 1.5 mm to approximately 5.0 mm. Preferably, it is in the range of approximately 2.0 mm to approximately 3.0 mm. A brake disc 1 with a radial outer oversize Ü1 of approximately 2.5 mm is particularly preferred. The radial inner oversize Ü2 can also be in the range of approximately 1.5 mm to approximately 5.0 mm, preferably in the range of approximately 2.0 mm to approximately 3.0 mm.

[0035] This blank of a brake disc 1 is now subjected to a coating in laser cladding welding, in which the surface 11a of the disc-like body 11 is provided with a coating consisting of two layers.

[0036] In the Fig. Figure 2 shows a phase of the coating process in which the coating of surface 11a is carried out by a tool 13. A laser beam 14, to which the coating material is also fed (not shown), is directed by the tool 13 onto the respective substrate. In the exemplary embodiment, the tool 13 moves radially, preferably from the inside out, at a feed rate V (see dashed line). A first layer B1 is applied to the surface 11a.

[0037] The first layer, B1, consists of stainless steel. This can preferably be an austenitic or ferritic stainless steel. For example, it is conceivable that the first layer consists of an austenitic chromium-nickel-molybdenum steel, which exhibits material properties corresponding to material 1.4404 according to standard EN 10027-2 or material 316L according to standard AISI. However, depending on the material properties of the brake disc, it is alternatively conceivable and has proven advantageous for the first layer to consist of a ferritic stainless steel, which exhibits material properties corresponding to material 1.4016 according to standard DIN EN 10027-2 or material 430L according to standard AISI.

[0038] Furthermore, the tool 13 is shown at the end of the coating of surface 11a with the first layer B1. It can be seen that the tool 13 is moved radially outwards only to the extent that the outer diameter dL of the laser beam 14, and thus a laser spot generated by it, just borders the outer diameter d1 of the brake disc 1. In this way, it is effectively prevented that the laser beam 14 can reach other areas uncontrollably and cause damage there. This also reduces overspray.

[0039] The same procedure is then followed for coating the first layer B1 with the second layer B2 (indicated by dashed lines). Here too, the coating tool 13 moves radially from the inside out. The first and second layers B1 and B2 form a coating B.

[0040] The second layer B2 comprises an iron alloy matrix, which also preferably consists of the aforementioned materials 316L or 430L. The hard particles may preferably consist of an alloy of titanium carbide and ferrochrome (TiC-FeCr) or of titanium carbide or tungsten carbide alone.

[0041] During the coating with the second layer B2, the tool 13 also moves radially outwards only so far that an outer diameter dL of the laser beam 14 and thus a laser spot generated by it just borders the outer diameter d1 of the brake disc 1.

[0042] Furthermore, it can be seen that in the area of ​​the laser beam 14, the thicknesses of layers B1 and B2 decrease continuously up to the outer diameter d2. Due to the excess material Ü1, this area of ​​decreasing coating B is located only radially outside the target outer diameter d2. Therefore, this does not adversely affect the quality of coating B in the subsequent "working area" of the brake disc 1. On the contrary, the thickness of coating B can be maintained continuously up to the target outer diameter d2.

[0043] In the Fig. Figure 3 shows an embodiment in which the tool 13 moves radially from the outside to the inside at a feed rate V during the application of the coating B (shown as a dashed line). It can be seen that at the end of the coating process, the tool 13 is only moved far enough that an outer diameter dL, and thus also a generated laser spot of the laser beam 14, just abuts the inner diameter d3 of the disk-like body 11, i.e., does not extend beyond it. This has the advantage that significantly less overspray enters the trough-like area 12.

[0044] It is also evident that in the area of ​​the laser beam 14, the thicknesses of layers B1 and B2 decrease continuously. Due to the oversize Ü2, this area of ​​decreasing coating B is located only radially outside the target inner diameter d4. Therefore, this does not adversely affect the quality of coating B in the subsequent "working area" of the brake disc 1. The thickness of coating B can thus be maintained continuously up to the target inner diameter d4.

[0045] In the Fig. Figure 4 shows how the brake disc 1 coated with coating B can be further processed: It is therefore conceivable that the second layer B2 could be processed by grinding using a suitable grinding tool WZ1. Grinding can bring the very hard, rough, and sooty surface of the second layer B2 to a surface quality suitable for contact with brake pads.

[0046] Before or after grinding, the coated brake disc 1 can undergo a turning process. Using a turning tool WZ2, the outer diameter d1 can be turned down to the target outer diameter d2. This eliminates any overspray in the area of ​​the outer diameter d1. Following this, a chamfer F1 (indicated by a dashed line) can be machined into the transition area between the disc-like body 11 and the coating B.

[0047] In the area of ​​the inner diameter d3, the inner diameter d3 can be turned to the target inner diameter d4 using a turning tool WZ3. Preferably, the majority of the trough-like recess 12 is turned out. This eliminates any overspray that may be present in the area of ​​the trough-like recess 12. Following this, a chamfer F2 (indicated by a dashed line) can be machined into the transition area from the disc-like body 11 to the coating B.

[0048] The chamfers F1 and F2 reduce the notch effect at these points and improve the suitability for applying a corrosion protection agent. Reference symbol list 1 brake disc 10 basic shapes 11 disc-shaped bodies 11a Area 12 trough-like depressions 13 tools 14 Laser beam B coating B1 first layer B2 second layer d1 outer diameter d2 Target outer diameter d3 inner diameter d4 Nominal inner diameter dL outer diameter laser beam D axis of rotation F1, F2 phases V Feed rate Ü1 Excess Ü2 excess WZ1 grinding tool WZ2 turning tool WZ3 turning tool

Claims

[1] Method for coating a brake disc (1) made of gray cast iron or steel, wherein the brake disc (1) has a base body (10) and at least one disc-like body (11) extending radially therefrom perpendicular to an axis of rotation (D) of the brake disc (1) with a surface (11a) whose surface normal is parallel to the axis of rotation (D), wherein the disc-like body (11) defines an outer diameter (d1) of the brake disc (1) and the outer diameter (d1) has a radial outer interference (Ü1) with respect to a nominal outer diameter (d2), wherein a coating (B) is applied to the surface (11a) of the disc-like body (11) by a tool (13) in laser cladding, the coating consisting of a first layer (B1) of stainless steel applied to the surface (11a) of the disc-like body (11) and of at least a second layer (B2) applied to the first layer (B1),which is a composite of an iron alloy matrix with embedded hard particles, , characterized by , that the coating (B) is carried out without prior processing by which the outer diameter (d1) of the brake disc (1) is reduced to the nominal outer diameter (d2). [2] Method according to claim 1, characterized by , that the brake disc (1) is used with a radial outer oversize (Ü1) in a range of 1.5 mm to 5.0 mm, preferably in a range of 2.0 to 3.0 mm. [3] Method according to claim 1 or 2, characterized by , that the brake disc (1) is used with a radial outer oversize (Ü1) of 2.5 mm. [4] Method according to any one of the preceding claims, characterized by, that when applying the coating (B) by laser cladding, the tool (13) is moved radially over the substrate to be coated so that an outer diameter (dL) of a laser beam (14) generated by the tool (13) is directly adjacent to the outer diameter (d1) of the brake disc (1). [5] Method according to any one of the preceding claims, characterized by , that the second layer (B2) is processed by grinding. [6] Method according to the preceding claim, characterized by , that the disc-like body (11) is machined by turning before or after grinding, thereby reducing its outer diameter (d1) to the target outer diameter (d2). [7] Method according to any one of the preceding claims, characterized by, that a brake disc (1) is used in which the base body (10) is connected to the disc-like body (11) via a trough-like recess (12), wherein an inner diameter (d3) of the disc-like body (11) is provided with a radial inner oversize (Ü2) relative to a nominal inner diameter (d4). [8] Method according to the preceding claim, characterized by , that when applying the coating (B) by laser cladding, the tool (13) is moved radially over the substrate to be coated so that an outer diameter (dL) of a laser beam (14) generated by the tool (13) is directly adjacent to the inner diameter (d3) of the disk-like body (11). [9] Method according to one of claims 6 and 7, characterized by , that the disc-like body (11) is machined by turning before or after grinding, thereby increasing its inner diameter (d3) to the target inner diameter (d4).

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