Brake Body Composite Friction Layer With Strong Coating Adhesion
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Solution Overview
Problem
Brake elements made from gray cast iron suffer from high weight, corrosion, and wear, leading to premature damage and particulate emissions, with existing coatings facing issues of adhesion, complexity, and high costs.
Innovation Solution
A brake element with a multi-layer coating comprising a first build-up layer of austenitic chromium-nickel-molybdenum steel and a second layer of an iron alloy matrix with intercalated tungsten carbide particles, applied using a controlled energy beam process to ensure optimal adhesion and thickness, reducing corrosion and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gray cast iron is used for brake elements, then high volumetric heat capacity and thermal shock resistance are achieved, but high weight, corrosion tendency, and wear occur
Solution Approach 1:
The patent applies composite materials by combining gray cast iron base material with multiple coating layers (austenitic steel layer and ceramic layer) to create a composite structure that maintains the thermal properties of the base material while adding corrosion and wear resistance, thereby reducing the need for heavy protective measures
2Reliability
If thermal spraying methods are used to apply coatings, then corrosion and wear protection is improved, but adhesion under thermomechanical stresses remains problematic
Solution Approach 1:
The patent uses a multi-layer composite coating structure where an austenitic steel intermediate layer is applied first to provide strong metallurgical bonding to the gray cast iron substrate, followed by a ceramic layer for corrosion and wear protection. This composite structure ensures both adhesion and protective functions
Solution Approach 2:
The austenitic steel intermediate layer acts as an intermediary between the gray cast iron substrate and the ceramic coating layer, providing a bonding interface that ensures strong adhesion while allowing the ceramic layer to fulfill its protective function
3Strength
If surface roughening by blasting or ultrasonic treatment is applied, then adhesion of thermal spray coating is improved, but process complexity increases
Solution Approach 1:
The austenitic steel intermediate layer serves as a mediator that provides strong bonding to the substrate, reducing the need for complex surface roughening treatments. The intermediate layer's metallurgical bonding capability simplifies the surface preparation process while ensuring adequate adhesion
4Strength
If intermediate layers are deposited chemically or electrochemically, then adhesion promoter function is achieved, but additional process steps and costs are incurred
Solution Approach 1:
The austenitic steel intermediate layer functions as an adhesion promoter through metallurgical bonding, combining the functions of intermediate layer and adhesion promoter in a single material layer, thereby simplifying the manufacturing process while ensuring strong bonding
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides high wear resistance and corrosion protection, minimizing particulate emissions and production costs while ensuring strong adhesion and durability.
Implementation Method 1
a energy beam is directed by at least one energy source onto a planar side of a planar base body of the brake element, a radiation intensity of the energy beam is maintained in a range of from 500 W/mm2 to 1500 W/mm2, at least in the second method operation during production of the second build-up layer
Data Source
AI summary
A brake element for a transportation vehicle, having a base body that is planar at least in some regions, to the planar sides of which at least two build-up layers are applied in each case at least in some regions. The build-up layers form a surface which, in the mounted state of the brake element on the transportation vehicle, serves as a friction surface for a brake pad. There is a bonding zone in which both a material of the base body and a material of a build-up layer adjacent to the base body are present, wherein the bonding zone has a thickness perpendicular to an areal extent of a planar side that is less than 10 μm.