Method for treating a layer structure for a brake disc and method for manufacturing a brake disc

Abstract

The invention relates to a method for treating a layer structure (1) for a brake disc (2), said layer structure comprising a carrier layer (3) and a cover layer (4), in which method the cover layer (4) is removed from the layer structure (1) by means of at least one liquid jet (11), and the brake disc can subsequently be recycled.

Description

[0001] 24-1009 PIF

[0002] 1

[0003] Method for treating a layer structure for a brake disc and method for manufacturing a brake disc

[0004] The invention relates to a method for treating a layer structure comprising a carrier layer and a cover layer for a brake disc according to claim 1. Furthermore, the invention relates to a method for manufacturing a brake disc according to claim 9.

[0005] DE 102015 122 325 A1 discloses a brake disc comprising an outer surface, a first and a second braking surface which are opposite each other and each bounded by the outer surface in order to form a first and second braking surface edge which are opposite each other, as well as several concentric grooves which are included on the first braking surface.

[0006] The object of the invention is to provide a method for treating a layer structure for a brake disc and a method for manufacturing a brake disc, so that the brake disc can be manufactured in a particularly resource-efficient manner.

[0007] This problem is solved according to the invention by a method for treating a layer structure for a brake disc with the features of claim 1 and by a method for manufacturing a brake disc with the features of claim 9. Advantageous embodiments of the invention are the subject of the dependent claims and the description.

[0008] A first aspect of the invention relates to a method for treating a layer structure for a brake disc, comprising at least one support layer and one cover layer. The layer structure can be referred to as a layer system. For example, the brake disc, which can be referred to as the first brake disc, has the layer structure, particularly in its fully manufactured state. The brake disc is intended, for example, as a brake disc for a motor vehicle. The motor vehicle is, for example, 24-1009 PIF

[0009] 2. Designed as a motor vehicle, in particular as a passenger vehicle. The shift structure can therefore be designed for the motor vehicle.

[0010] The brake disc, for example, is part of a braking system, particularly for a motor vehicle. The braking system can be understood to be, in particular, a mechanical brake, especially a friction brake. Specifically, the braking system is designed to reduce the speed of the motor vehicle to which it belongs, preferably in a controlled manner. This can also be referred to as braking or deceleration.

[0011] The layer structure includes a carrier layer, which can be referred to as the first layer. Thus, the carrier layer can be the first layer of the layer structure. The carrier layer, which can also be referred to as the substrate, is, for example, made of a cast material. In other words, the carrier layer is produced by casting. It can therefore be provided that the carrier layer is produced by casting. The carrier layer is, for example, designed as the base body of the brake disc. Furthermore, the layer structure includes at least the cover layer, which is distinct from the carrier layer and can be referred to as the second layer. The cover layer is, for example, designed as a friction layer and / or as a wear layer of the layer structure, particularly of the brake disc. Preferably, the cover layer is reinforced with a hard material, that is, it is designed as a hard-material-reinforced layer.

[0012] In order to manufacture a brake disc, for example the first brake disc or a second brake disc, which is different from the first, in a particularly resource-efficient and therefore particularly sustainable manner, the surface layer is removed from the layer structure, particularly the substrate, by means of at least one liquid jet, for example, provided or generated by at least one liquid jet supply device, particularly at least predominantly or at least substantially. In other words, the surface layer is acted upon, particularly directly, by means of the at least one liquid jet in order to remove the surface layer from the layer structure or the substrate, that is, to detach it from the layer structure or the substrate.The liquid jet is preferably a high-pressure liquid jet. The liquid jet is, for example, a water jet. 24-1009 PIF.

[0013] 3

[0014] The invention is based in particular on the following findings and considerations: Brake discs can generally be coated using a two-layer process. Even wear-resistant layers, for example those reinforced with a hard material, can still be subject to a certain degree of abrasive wear. At the end of a service life, particularly one that can be expected, of the first brake disc, it may be necessary to recycle a brake disc core, i.e., at least the carrier layer, especially without further coatings. However, recycling can be hindered by a material of the surface layer, for example, the hard material.For example, in recycling, it is crucial to prevent hard materials used in or for the surface layer from being used in a melting process for casting, as this could lead to contamination of the melt pool, for instance, by unwanted chemical elements from the hard materials. Alternatively, the first brake disc, which may be newly manufactured or to be manufactured, could have production defects. This might necessitate, for example, during the production of the first brake disc, recoating the disc body—that is, at least the substrate layer—with one or more coatings. This minimizes scrap, as instead of completely remanufacturing the first brake disc, the surface layer can be removed and then reapplied.

[0015] The use of at least one fluid jet allows the top layer to be removed from the layer structure or the substrate in a particularly efficient, energy-efficient, and / or safe manner, particularly with process reliability. This enables the removal of the top layer, reinforced with a hard material, for example, in a particularly efficient, environmentally friendly, and / or process-reliable way, to make the first brake disc recyclable and / or to recoat a first brake disc with production defects. After removing the top layer, a new brake disc can be manufactured from the remaining layer structure, i.e., at least from the substrate, particularly by applying a new top layer. This new brake disc could be, for example, the aforementioned second brake disc.The second brake disc, for example, is a new brake disc produced by recycling the first brake disc. Thus, after removing the top layer, the brake disc can undergo a new casting process (24-1009 PIF).

[0016] 4. This allows for a complete product development process to be repeated. Alternatively, the layer structure, meaning at least the base layer, of the first brake disc can be recoated with the top layer after the top layer has been removed, in order to correct the aforementioned production error. The first and / or second brake disc can thus be manufactured in a particularly resource-efficient manner.

[0017] In a further embodiment, the surface layer, particularly in its base material, comprises embedded hard particles. In other words, hard particles are embedded in the surface layer, especially in its base material. This allows the surface layer, along with the embedded hard particles, to be removed from the layer structure or the substrate by means of the at least one liquid jet, particularly when the surface layer is subjected to the at least one liquid jet, for collection and recycling purposes. This means that the hard particles, together with the surface layer, can be detached from the layer structure or the substrate by the liquid jet.This prevents the hard particles from entering the melt pool, thus making the coating structure and / or the brake disc recyclable. The term "coating base" can refer in particular to a matrix. For example, the coating base or this matrix is ​​at least partially, and in particular at least predominantly or completely, made of metal. Preferably, the hard particles are made of at least one carbide and / or at least one ceramic. In other words, the hard particles are carbide particles and / or ceramic particles. The hard particles can significantly increase the hardness of the coating, thereby significantly increasing the wear resistance of the coating structure, especially the brake disc.In order to comply with legally required brake emissions, for example based on EU-7 regulations, the brake disc or the layer structure is provided with the coating containing the hard material in the form of the top layer, whereby the hard material in this case consists in particular of the hard material particles.

[0018] In a further embodiment, the layer structure is provided for to have at least one intermediate layer, in particular one arranged directly between the support layer and the cover layer, and in particular one that is different from the support layer and the cover layer, which can be referred to as a third layer. In other 24-1009 PIF

[0019] 5

[0020] In other words, the intermediate layer extends at least partially, and in particular predominantly or completely, between the carrier layer and the top layer. This means that the carrier layer and the top layer are connected to each other via the intermediate layer, in particular directly. Thus, the layer structure preferably comprises several layers, these layers being the first layer, the top layer (also referred to as the second layer), and the third layer. The top layer is preferably removed from the intermediate layer by means of at least one liquid jet, in particular directly. This means that by applying the at least one liquid jet to the top layer, the top layer is detached or separated from the intermediate layer, in particular directly. Preferably, the intermediate layer remains in the layer structure, i.e., attached to the carrier layer.In other words, the at least one liquid jet, directed at the top layer and the intermediate layer, removes only the top layer from the layer structure or the substrate. This embodiment is based in particular on the finding that the liquid jet allows the top layer to be removed from the intermediate layer particularly effectively, especially in a very efficient and environmentally friendly manner, and in particular without removing the intermediate layer from the substrate, thus allowing the intermediate layer to remain attached to the substrate. This enables the intermediate layer to be reused, for example, in the aforementioned recycling process.Alternatively, the intermediate layer can also be removed from the carrier layer after the top layer has been removed, allowing the intermediate layer to be used for other purposes, such as another recycling process. In this case, however, the top layer and the intermediate layer can be removed separately from the carrier layer, meaning that after removal they are essentially separated, enabling particularly efficient and low-effort recycling of the intermediate layer.

[0021] In a further embodiment, it is provided that the intermediate layer is formed, in particular at least partially, predominantly, or completely, from steel. Preferably, the intermediate layer is formed, in particular at least partially, predominantly, or completely, from at least one material with a multiphase microstructure, preferably with a two-phase microstructure, for example, duplex steel. This means that the material of the intermediate layer has the multiphase microstructure, which is preferably a two-phase microstructure, with this material being, for example, preferably duplex steel. In other words, the intermediate layer has the 24-1009 PIF

[0022] Six multiphase microstructures are observed. Thus, the material of the intermediate layer can be duplex steel. This means that the intermediate layer is at least partially, and in particular at least predominantly or completely, formed of duplex steel. The microstructure can be understood, in particular, as the microstructure of the material. The microstructure can describe the arrangement and order of the material's constituents at the visible and microscopic levels. In particular, the term "microstructure" denotes the characteristics of a whole, of those partial volumes, each of which is primarily homogeneous with respect to its composition and spatial arrangement of its constituents relative to a fixed axis system placed within the material. In particular, the microstructure is characterized by the type, shape, size, distribution, and / or orientation of its constituents.The intermediate layer can significantly increase the ductility and / or strength of the layer structure, particularly to enable it to withstand thermally and / or mechanically demanding applications. This also significantly enhances the wear resistance of the layer structure. This embodiment is based, in particular, on the finding that the top layer can be effectively removed from the intermediate layer formed from the multiphase structure, especially duplex steel, by means of at least one liquid jet.

[0023] In a further embodiment, the intermediate layer is applied to the substrate by laser powder deposition, preferably by high-speed laser powder deposition. In other words, the intermediate layer is produced by laser powder deposition. Thus, the substrate can be coated with the intermediate layer by laser powder deposition. This allows the top layer to be removed from the intermediate layer with particular process reliability using the liquid jet, for example, without the intermediate layer being detached from the substrate.Laser powder deposition welding can be understood as, in particular, a process in which a surface coating is applied to a workpiece, i.e., in this case, to the substrate, by melting and, in particular, simultaneously applying a powdered material, for example, a metal powder. Examples of laser powder deposition welding include HS-LMD (High-Speed ​​Laser Deposition) and EH LA (Extreme High-Speed ​​Laser Deposition). 24-1009 PIF.

[0024] 7

[0025] In a further embodiment, it is provided that the top layer is or is kinetically sprayed, preferably by cold gas spraying. In other words, at least one manufacturing step for producing the top layer or the layer structure comprises a kinetic spraying process, preferably cold gas spraying. Thus, it is particularly provided that the intermediate layer is or is coated with the top layer by means of the kinetic spraying process. The kinetic spraying preferably takes place at a speed greater than 300 m / s. The speed can be understood in particular as the spraying speed at which, for example, material is applied, in particular sprayed, to the intermediate layer to form the top layer. Preferably, the top layer is or is produced by means of cold gas spraying.Therefore, it is specifically intended that the intermediate layer is or will be coated with the top layer by means of cold gas spraying, which means that the kinetic spraying process can be cold gas spraying.

[0026] Cold gas spraying can be understood as a coating process in which a coating material, that is, in particular a material intended for the top layer, is applied in powder form at very high or high speed to a substrate, that is, in this case, the intermediate layer. For this purpose, a process gas, such as nitrogen or helium, heated to less than 100 degrees Celsius, preferably more than 1000°C, for example, at least substantially 1100°C, can be accelerated to supersonic speed by expansion in a Laval nozzle. Subsequently, powder particles of the material can be injected into a gas jet of the process gas.The injected powder particles, which can also be called spray particles, can be accelerated to such a high speed that, unlike other thermal spraying processes, they can form a dense and firmly adhering layer upon impact with the substrate material, i.e., the intermediate layer, even without prior melting or smelting. Cold gas spraying can also be referred to as "gold gas spray" in English.

[0027] Kinetic spraying, and especially cold gas spraying, allows for a particularly hard surface layer, thus significantly increasing its hardness. The substrate layer, particularly when formed from the casting material, can be softer compared to the surface layer. 24-1009 PIF

[0028] 8. The intermediate layer may be softer, meaning it can be moderately hard compared to the top layer and the substrate layer—harder than the substrate layer and softer than the top layer. This can be due to a ferritic phase in the intermediate layer, as the ferritic phase can impart hardness and / or strength. This allows the intermediate layer to act as a mediator between the substrate layer and the top layer. In particular, this means that if cracks occur in the top layer, they can not only penetrate through the intermediate layer to the substrate layer, but can also be contained by the intermediate layer. The intermediate layer can thus absorb crack tips, stopping or slowing down their propagation. This can significantly increase the corrosion resistance of the layer structure, especially when cracks are present or imminent.Furthermore, the tensile strength of the layer structure can be significantly increased.

[0029] The kinetically sprayed, especially cold gas sprayed, top layer allows for particularly efficient and, in particular, highly reliable removal of the top layer using at least one liquid jet. This enables the first and second brake discs to be manufactured in a particularly resource-efficient manner.

[0030] In a further embodiment, it is provided that the top layer is subjected to pressure of at least 500 bar and / or a maximum of 10,000 bar by means of at least one liquid jet for removal from the layer structure, i.e., for removal from the carrier layer and / or the intermediate layer. In other words, the at least one liquid jet is generated or provided by the liquid jet supply device, wherein a liquid forming the at least one liquid jet is brought to a pressure of at least 500 bar and / or a maximum of 10,000 bar by means of the liquid jet supply device, in particular compressed.The pressure of the liquid can be at least 500 bar and / or at most 10,000 bar, particularly when and while the liquid flows through the liquid jet supply device and / or when the liquid is located within the liquid jet supply device, for example, in a tank. Thus, the high-pressure liquid jet, for example, a high-pressure water jet, can be used in a pressure range of 500 to 10,000 bar, especially for removing the top layer. This allows the top layer to be removed with particularly low effort and with particularly reliable processes, meaning it is exceptionally effective. 24-1009 PIF.

[0031] 9

[0032] In a further embodiment, it is provided that the top layer is supplied with at least one liquid jet by means of at least one liquid jet supply device. The liquid jet supply device has at least one nozzle with a cross-section through which the liquid flows or can flow, with a diameter of at least 0.2 millimeters and / or a maximum of 1.0 millimeter. This means that the nozzle has at least the cross-section through which the liquid flows or can flow, which has a diameter of at least 0.2 millimeters and / or a maximum of 1.0 millimeter. The at least one liquid jet can thereby be precisely adjusted in such a way as to be able to detach the top layer from the layer structure in a particularly reliable manner, and in particular to ensure that the intermediate layer can remain attached to the substrate layer.

[0033] Alternatively or additionally, the at least one liquid jet preferably strikes the surface layer at a substantially perpendicular angle, particularly directly, especially to effect the aforementioned removal of the surface layer from the layer structure. In other words, the surface layer is struck by the at least one liquid jet at or below a perpendicular angle. The angle can be understood to be, in particular, the angle at which the at least one liquid jet strikes the surface layer. This angle, which can also be referred to as the angle of attack, is therefore preferably at least substantially 90 degrees. This allows the surface layer to be removed from the layer structure, in particular the substrate layer and / or the intermediate layer, with particular reliability.

[0034] A second aspect of the invention relates to a method for manufacturing, in particular recycling, a brake disc. Advantages and advantageous embodiments of the first aspect of the invention are to be regarded as advantages and advantageous embodiments of the second aspect of the invention, and vice versa. The brake disc can be the first or the second brake disc, which can also be referred to as a new brake disc.

[0035] In order to manufacture the first and / or second brake disc in a particularly resource-efficient manner, the brake disc, in particular the first and / or the second brake disc, is made from the layer structure treated by means of a method according to the first aspect of the invention, which in particular includes at least the 24-1009 PIF

[0036] 10

[0037] The layer structure, which has a carrier layer, is manufactured. In other words, the treated layer structure, that is, the layer structure freed from the top layer, is used to manufacture the brake disc, that is, the first and / or second brake disc.

[0038] In a further embodiment, the layer structure, particularly the existing carrier layer and / or the existing intermediate layer, which has been freed from its top layer, is provided with a new top layer, preferably by means of kinetic spraying, for example by means of cold gas spraying. This can be understood to mean, in particular, the following: For example, after the end of a service life intended for the first brake disc, the top layer can be removed from the layer structure, in particular from the carrier layer and / or the intermediate layer, by means of the method according to the first aspect of the invention. Subsequently, the new top layer, which can also be referred to as the second top layer, can be applied to the remaining layer structure, i.e., for example, to the base body of the first brake disc, thereby producing the second brake disc, which can be referred to as the new brake disc.Thus, the second or new brake disc can at least have the substrate layer of the first brake disc and the new top layer, but in particular not the top layer of the first brake disc, also referred to as the old top layer. Therefore, the second brake disc is specifically free of the old top layer. The method can be understood as a recycling process, especially for hard-coated brake discs. Alternatively, it may be that the old top layer was applied defectively to the substrate layer and / or the intermediate layer, and thus does not meet quality requirements. The defective old top layer can be removed from the layer structure of the first brake disc, in particular from the substrate layer and / or the top layer, using the method according to the first aspect of the invention.Subsequently, particularly for manufacturing or repairing the first brake disc, the new top layer can be applied to the layer structure, that is, at least to the substrate layer and / or the intermediate layer, especially to replace the old top layer of the first brake disc. This allows the first brake disc to have the new top layer and, in particular, to be free of the old top layer.

[0039] In an alternative embodiment, a new layer structure comprising at least one new support layer is produced from the layer structure by means of casting, which, in particular subsequently, is combined with the new top layer, for example by means of 24-1009 PIF.

[0040] 11. The process is carried out by kinetic spraying, preferably by means of cold gas spraying. This can be understood in particular as follows: The layer structure of the first brake disc can be freed from the top layer by means of the method according to the first aspect of the invention. Subsequently, this layer structure, in particular freed from the top layer, can be melted down, whereby a new layer structure is cast for the second brake disc, which has at least one new carrier layer. This new layer structure, that is to say in particular the new carrier layer and / or a new intermediate layer of the new layer structure, is then coated with the new top layer, in particular to produce the second or new brake disc.The layer structure of the first brake disc, freed from its top layer, can thus be recycled to manufacture the new, second brake disc, whereby the second brake disc or the new layer structure can be manufactured anew from a material of the layer structure by means of casting.

[0041] Further features of the invention will become apparent from the claims, the figures, and the description of the figures. The features and combinations of features mentioned above in the description, as well as the features and combinations of features mentioned below in the description of the figures and / or shown in the figures alone, are not only usable in the combinations specified, but also in other combinations or on their own.

[0042] The invention will now be explained in more detail with reference to a preferred embodiment and the drawings. The drawings show:

[0043] The drawing shows in the single figure a schematic representation of a layer structure to illustrate a method according to the invention.

[0044] Fig. 1 shows a schematic partial sectional view of a layer structure 1, which in this case is a layer structure 1 of a brake disc 2, which can also be referred to as the first brake disc 2. Thus, the first brake disc 2 in this case has the layer structure 1. The brake disc 2 is, for example, a brake disc for a motor vehicle.

[0045] The first brake disc 2, for example, has a base body designed as a brake disc hub, which can also simply be referred to as a hub. Furthermore, the brake disc 2 has, for example, a friction ring arranged, in particular directly, on the brake disc hub. Thus, for example, on a 24-1009 PIF

[0046] 12

[0047] Brake pads of the brake system, which has a brake disc 2, are attached to the brake caliper of a brake assembly. These pads act on the brake disc 2, particularly via the friction ring, to brake the motor vehicle, for example, by decelerating the rotational movement of at least one wheel of the motor vehicle. Thus, the brake pad, particularly via the friction ring, can rub against the brake disc 2, thereby generating braking of the motor vehicle by converting kinetic energy into heat. This means that the friction ring is specifically designed for the mechanical action of the brake pad. The friction ring can have the layer structure 1, or the friction ring can be provided with the layer structure 1.

[0048] As shown in Fig. 1, the layer structure 1 comprises a support layer 3 and a cover layer 4, which is formed separately from the support layer 3. The support layer 3 can be referred to as the support material, substrate, or carrier material. In the exemplary embodiment, the layer structure 1 comprises an intermediate layer 5 arranged between the support layer 3 and the cover layer 4, which is formed separately from the support layer 3 and the cover layer 4 and is made of a material 6 with a multiphase structure. In other words, the support layer 3 and the cover layer 4 are spaced apart from each other, at least in certain regions, with the intermediate layer 5 being arranged at this distance.Thus, on a first side 7 of the intermediate layer 5, the carrier layer 3 adjoins, in particular directly, and on a second side 8 of the intermediate layer 5, which differs from the first side 7 and in particular faces away from the first side 7, the cover layer 4 adjoins, in particular directly. This means that the carrier layer 3, in particular on the first side 7, is provided or coated with a coating in the form of the intermediate layer 5, which, on a side facing away from the carrier layer 3, in particular on the second side 8, is provided or coated with a coating in the form of the cover layer 4. In the present case, the carrier layer 3 and the cover layer 4 are connected to each other by means of the intermediate layer 5, in particular directly. In particular, the carrier layer 3 and the cover layer 4 adjoin the intermediate layer 5 along one direction, for example on both sides.

[0049] In the present case, the cover layer 4 has an outer surface 9 that points outwards, particularly with respect to the brake disc 2 or the layer structure 1. Thus, the brake disc 2 can be bounded by the outer surface 9, or even formed by the outer surface 9, particularly in the axial direction. (See 24-1009 PIF)

[0050] In section 13, the top layer 4 is present, in particular the outer surface 9 of the top layer 4, designed, for example, for direct engagement with the brake pad. This means that, for example, the brake pad can mechanically act upon the brake disc 2 via the top layer 4, in particular directly, in order to decelerate the vehicle. The top layer 4 can thus be an uppermost or outermost layer of the layer structure 1.

[0051] Figure 1 illustrates a method for treating the layer structure 1, particularly that of the first brake disc 2. To enable the particularly resource-efficient production of the first brake disc 2, or of a second brake disc different from the first brake disc 2, the top layer 4 is removed from the layer structure 1, particularly from the substrate layer 3 and / or the intermediate layer 5, by means of at least one liquid jet 11, generated or supplied in particular by a liquid jet supply device 10. This allows the brake disc 2 to be subsequently recycled, for example. Preferably, several such liquid jets 11 are used in the method. By removing the top layer 4, the remaining material of the first brake disc 2 can be fed into a recycling process for the production of the second brake disc, i.e., a new brake disc.Therefore, it is specifically intended that this recycling process, i.e., the production of the second brake disc, will actually be carried out. The remaining material can comprise at least the carrier layer 3, in particular the carrier layer 3 and the intermediate layer 5. The second brake disc can thus be produced from the treated layer structure 1, whereby the layer structure 1 is provided, for example, with a new cover layer 4, which is structurally identical to the cover layer 4. After the removal of the cover layer 4, the new cover layer 4 can thus be applied, so to speak, to an "old base body" of the old brake disc 2 in order to produce or form the second brake disc.The second brake disc can alternatively be manufactured from the treated layer structure 1, whereby a new layer structure, comprising at least one new support layer, is produced from layer structure 1 by casting, for example, and then covered with the new surface layer. Melting for casting takes place, for example, in a casting furnace, also simply called a furnace. Thus, a base body for the second brake disc can be recast, so to speak, from layer structure 1 of the first brake disc, now freed from surface layer 4. The new support layer is, for example, structurally identical to support layer 3. 24-1009 PIF.

[0052] 14

[0053] Alternatively, the first brake disc 2 is manufactured from the layer structure 1. This is done, for example, if the top layer 4 is defective, i.e., incorrectly applied. This defective top layer 4 can be removed from the layer structure 1 by means of at least one liquid jet 11, as explained above, whereby the top layer 4, or a corresponding new top layer 4, can then be reapplied to the substrate 3 and / or the intermediate layer 5 to manufacture the first brake disc 2. This avoids rejects in the manufacture of the first brake disc 2, since, for example, the substrate 3 can be reused.

[0054] For example, the top layer 4 is removed from the intermediate layer 5 by means of the at least one liquid jet 11, wherein the intermediate layer 5 preferably remains in the layer structure 1 or on the support layer 3, i.e. preferably is not removed.

[0055] For example, the intermediate layer 5 is made of steel, such as 316L or 430L. Preferably, the intermediate layer 5 is made of material 6 with a multiphase, for example, two-phase, microstructure. The multiphase microstructure is thus, for example, a two-phase microstructure. Particularly preferably, the material 6 of the intermediate layer 5 is duplex steel. The intermediate layer 5 can therefore be made at least partially, and in particular at least predominantly or completely, of duplex steel.

[0056] For example, the support layer 3 is formed from a cast material, in particular a metallic one, which is, for example, gray cast iron. For example, the cover layer 4, in particular a base body 17 of the cover layer 4, is formed at least partially, in particular at least predominantly or completely, from a metal. The base body 17 of the cover layer 4 can also be referred to as the cover layer base body. The metal is, for example, an alloy, such as a titanium alloy. The cover layer 4 can therefore also be referred to as the titanium cover layer. The titanium alloy is, for example, Ti-6AL-4V, which can also be referred to as Ti64. Alternatively, the metal of the support layer 3 is, for example, steel, in particular a stainless steel. 24-1009 PIF

[0057] 15

[0058] In the exemplary embodiment, the cover layer 4, in particular the base layer, has hard particles 12 embedded within it. The hard particles 12 are made of a carbide, for example tungsten carbide, niobium carbide, titanium carbide, or silicon carbide, or of ceramic. Thus, the cover layer 4 can contain a ceramic component and / or a carbide component. Because the cover layer 4 contains the embedded hard particles 12, it is removed from the layer structure 1, in particular from the support layer 3 and / or the intermediate layer 5, by means of the at least one liquid jet 11, allowing the cover layer 4 to be collected, for example, for recycling.

[0059] Preferably, the top layer 4 and the intermediate layer 5 are produced by different coating processes. It is particularly preferred that the intermediate layer 5 is produced by laser powder deposition, preferably ultra-high-speed laser powder deposition. In other words, the intermediate layer 5 is applied to the substrate 3 by laser powder deposition, in particular ultra-high-speed laser powder deposition. Thus, the intermediate layer 5 is chemically bonded to the substrate 3 by laser powder deposition. The top layer 4 is, for example, kinetically sprayed, preferably by cold gas spraying.Thus, the different coating processes can include laser powder deposition (LMD) and kinetic spraying, especially cold gas spraying (CGS). This allows for significant differences in the stress states of the top layer 4 and the intermediate layer 5, enabling the targeted adjustment of their respective properties. This, in turn, can significantly improve the corrosion resistance of the layer structure 1. For example, the top layer 4 and the intermediate layer 5 are particularly well separable when the substrate 3 is made of a titanium alloy, especially TI64.

[0060] Preferably, the top layer 4 is subjected to a pressure, in particular a liquid pressure, of at least 500 bar and / or a maximum of 10,000 bar by means of at least one liquid jet 11 in order to remove it from the layer structure 1, in particular from the carrier layer 3 and / or the intermediate layer 5. 24-1009 PIF

[0061] 16

[0062] Therefore, the liquid jet 11 can be a high-pressure liquid jet, for example a high-pressure water jet.

[0063] In the exemplary embodiment, the top layer 4 is supplied with at least one liquid jet 11 by means of the liquid jet supply device 10. The liquid jet supply device 10 has at least one nozzle 13 with a cross-section through which the liquid flows, having a diameter of at least 0.1 millimeters and / or a maximum of 1.0 millimeters. Preferably, however, the liquid jet supply device 10 has several such nozzles 13, which, or rather their respective cross-sections, are through which the liquid flows to form one of the liquid jets 11. For example, at least two and / or a maximum of 18 such nozzles 13 are provided. Thus, several individual nozzles in the form of the aforementioned nozzles 13 can be held in a nozzle holder, in particular a common one.This allows a specific liquid jet pulse to be precisely adjusted, which, for example, is specifically adapted to removing the existing top layer 4. This enables particularly reliable removal of the top layer 4. Other material in the layer structure 1, i.e., material different from the top layer 4, is not affected by the liquid jet 11. In particular, highly precise stripping can be achieved. The respective nozzle 13 is designed, for example, as a round jet nozzle. Thus, depending on the thickness and bond of the top layer 4, also referred to as the friction layer, to the intermediate layer 5, a corresponding set of parameters can be adjusted. Various nozzle designs can be used for this purpose.Preferably, multi-jet circular jet nozzles with a number of outlets n = 2 to 18 and a diameter of each nozzle opening of 0.2 to 1.0 millimeters should be selected.

[0064] Furthermore, in the exemplary embodiment, the liquid jet 11, in particular the respective jet, strikes the surface layer 4 at least substantially perpendicularly, and in particular directly. In other words, the angle of attack is ideally 90 degrees, but can also be varied. For example, the liquid jet supply device 10, in particular a pump, is operated at a speed of at least 100 revolutions per minute and / or up to a maximum of 5000 revolutions per minute. For example, the aforementioned pressure can be provided or generated by the pump. Thus, the liquid 24-1009 PIF

[0065] 17, for example, brought to the stated pressure or compressed by means of the pump.

[0066] When the surface layer 4 is sprayed with at least one jet of liquid 11, the distance provided between the nozzle 13, in particular the respective nozzle 13, and the surface layer 4 is, for example, at least 1 millimeter and / or at most 1000 millimeters. Thus, the distance, also referred to as the nozzle distance, can be varied between 1 millimeter and 1000 millimeters.

[0067] After removal of the top layer 4, a base component of the first brake disc 2, for example at least the carrier layer 3, can be reused. This includes, as already explained, the production of the second brake disc, in particular by recycling at least the carrier layer 3, or the reapplication of the top layer 4 to the first brake disc 2, for example to correct production defects. The intermediate layer, also referred to as the steel medium, can be disposed of separately from residues of the top layer 4 (also referred to as the hard coating) or used for other purposes, such as in road construction.

[0068] Numerals, such as "first", "second", "third", etc., are intended solely for differentiation and do not, in particular, indicate an order. This means that the corresponding numerals can be interchanged arbitrarily.

[0069] -1009 PIF

[0070] 18

[0071] Reference symbol list

[0072] Layer structure of first brake disc

[0073] carrier layer

[0074] Top layer

[0075] Intermediate shift

[0076] Intermediate layer material first side second side

[0077] Outside

[0078] Liquid jet delivery device

[0079] liquid jet

[0080] hard particles

[0081] nozzle

Claims

24-1009 PIF 19 Patent claims 1. Method for treating a layer structure (1) comprising a support layer (3) and a cover layer (4) for a brake disc (2), wherein the cover layer (4) is removed from the layer structure (1) by means of at least one liquid jet (11).

2. Method according to claim 1, characterized in that the cover layer (4) has embedded hard material particles (12), which are formed in particular from at least one carbide and / or from at least one ceramic, whereby the cover layer (4) together with the hard material particles (12) is removed from the layer structure (1), in particular for collection for recycling, by means of the at least one liquid jet (11).

3. Method according to claim 1 or 2, characterized in that the layer structure (1) has an intermediate layer (5) arranged between the support layer (3) and the cover layer (4), from which the cover layer (4) is removed by means of the at least one liquid jet (11), wherein the intermediate layer (5) preferably remains in the layer structure (1).

4. Method according to claim 3, characterized in that the intermediate layer (5) is made of steel.

5. Method according to claim 3 or 4, characterized in that the intermediate layer (5) is applied to the carrier layer (3) by means of laser powder deposition welding, preferably high-speed laser powder deposition welding. 24-1009 PIF 20 6. Method according to one of the preceding claims, characterized in that the top layer (4) is kinetically sprayed, preferably cold gas sprayed.

7. Method according to one of the preceding claims, characterized in that the top layer (4) is subjected to a pressure of at least 500 bar and / or a maximum of 10,000 bar for removal from the layer structure (1) by means of the at least one liquid jet (11).

8. Method according to one of the preceding claims, characterized in that • the top layer (4) by means of at least one liquid jet supply device (10) which has at least one nozzle (13) with a cross-section through which the liquid flows having a diameter of at least 0.2 millimeters and / or a maximum of 1.0 millimeter, with which at least one liquid jet (11) is applied, and / or • that at least one jet of liquid (11) strikes the surface layer (4) at least substantially perpendicularly.

9. Method for manufacturing a brake disc, in particular a new and / or remanufactured one, in which the brake disc is manufactured from the layer structure (1) treated by means of a method according to one of the preceding claims.

10. Method according to claim 9, characterized in that • the layer structure (1) is provided with a new top layer or • a new layer structure comprising at least one new support layer (3) is produced from the layer structure (1) by means of casting, which is provided with a new top layer.

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