Dual Carbide Brake Disc Coating for Wear and Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional brake discs made of aluminium, grey cast iron, or steel suffer from excessive wear and surface oxidation, leading to flaking of protective coatings, which compromises their durability and performance.
Innovation Solution
A method involving the deposition of a base protective coating of chromium carbide (Cr3C2) and nickel-chromium (NiCr) followed by a surface protective coating of tungsten carbide (WC) and cobalt (Co) using HVOF, HVAF, or KM techniques, providing enhanced bonding strength and reducing flaking, with specific compositions and thicknesses to optimize wear resistance and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective coating is applied to grey cast iron or steel brake discs, then wear resistance is improved and oxidation is reduced, but the coating is subject to flaking and detachment
Solution Approach 1:
The patent changes the chemical composition parameters of the coating by eliminating free carbon and specifying precise proportions of tungsten carbide (85-95%), cobalt (5-10%), and chromium (1-5%). This compositional parameter change resolves the flaking issue while maintaining wear resistance and oxidation protection
Solution Approach 2:
The patent uses a composite coating material consisting of multiple components (tungsten carbide, cobalt, chromium) combined in specific ratios. This composite structure provides both wear resistance and oxidation protection while eliminating the flaking problem associated with traditional coatings containing free carbon
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 significantly reduces flaking and enhances the durability and wear resistance of brake discs, maintaining performance over time while preventing oxidative damage and stress-induced cracking, thus offering superior tribological and corrosion-resistant properties.
Implementation Method 1
depositing on the disc a layer of chromium carbide (Cr3C2) and nickel-chromium (NiCr) in particulate form with HVOF (High Velocity Oxygen Fuel), HVAF (High Velocity Air Fuel) or KM (Kinetic Metallisation) technique
Implementation Method 2
depositing on the disc a layer of chromium carbide (Cr3C2) and nickel-chromium (NiCr) in particulate form with HVOF (High Velocity Oxygen Fuel), HVAF (High Velocity Air Fuel) or KM (Kinetic Metallisation) technique
Implementation Method 3
depositing on the disc a layer of chromium carbide (Cr3C2) and nickel-chromium (NiCr) in particulate form with HVOF (High Velocity Oxygen Fuel), HVAF (High Velocity Air Fuel) or KM (Kinetic Metallisation) technique
Implementation Method 4
depositing, over said base protective coating, a material in particulate form consisting of tungsten carbide (WC) and cobalt (Co) with HVOF (High Velocity Oxygen Fuel), HVAF (High Velocity Air Fuel) or KM (Kinetic Metallisation) technique
Implementation Method 5
depositing, over said base protective coating, a material in particulate form consisting of tungsten carbide (WC) and cobalt (Co) with HVOF (High Velocity Oxygen Fuel), HVAF (High Velocity Air Fuel) or KM (Kinetic Metallisation) technique
Implementation Method 6
depositing, over said base protective coating, a material in particulate form consisting of tungsten carbide (WC) and cobalt (Co) with HVOF (High Velocity Oxygen Fuel), HVAF (High Velocity Air Fuel) or KM (Kinetic Metallisation) technique
Implementation Method 7
protects the surface of the grey cast iron base from oxidation, thus avoiding the formation of a layer of rust
Implementation Method 8
the protective coating reduces wear of the disc and, on the other, protects the surface of the grey cast iron base from oxidation
Data Source
AI summary
A method for manufacturing a brake disc may have the following operating steps: a) preparing a brake disc, with a braking band and provided with two mutually opposite braking surfaces; b) depositing on the disc a layer of chromium carbide (Cr3C2) and nickel-chromium (NiCr) in particulate form forming a base protective coating; and c) depositing over the base protective coating a material in particulate form with the tungsten carbide (WC) and cobalt (Co) forming a surface protective coating. Both protective coatings are created with HVOF (High Velocity Oxygen Fuel), HVAF (High Velocity Air Fuel) or KM (Kinetic Metallisation) technique.