Laser-Welded Brake Disc Coating for Edge Corrosion Resistance
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Solution Overview
Problem
Conventional brake discs made of gray cast iron suffer from high corrosion susceptibility and wear, leading to premature failure, while ceramic discs are too expensive for mass production, and existing coatings fail to provide lasting corrosion protection due to delamination and flaking.
Innovation Solution
A brake disc design with a laser-welded wear protection layer extending beyond the friction surface into an angled region, ensuring a gap-free application and using materials like non-oxide ceramics or metal alloys for enhanced durability and corrosion resistance, combined with a method of laser deposition welding to maintain uniform layer thickness and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a wear protection layer is applied only on the friction surface, then the friction surface gains wear resistance, but the interface between the wear protection layer and base body becomes exposed to corrosion at the edges
Solution Approach 1:
The wear protection layer is extended from the two-dimensional friction surface into the third dimension by covering the angled region and vertical side surface. This dimensional extension creates a protective barrier that seals the interface area, preventing corrosive media from reaching the vulnerable interface between the wear protection layer and base body.
Solution Approach 2:
The wear protection layer acts as a continuous protective film that conforms to the complex geometry of the brake disc surface, including the friction surface, angled region, and vertical side surface. This thin film provides comprehensive corrosion protection while maintaining the structural integrity of the base body.
2Object-affected harmful factors
If conventional corrosion protection coatings are applied, then temporary corrosion protection is achieved, but they fail to provide lasting protection due to delamination and flaking during braking
Solution Approach 1:
The solution combines a wear protection layer made of non-oxide ceramic material or metal alloy with increased wear resistance with the base body of gray cast iron or steel. This composite structure provides both wear resistance on the friction surface and corrosion protection at the interface, creating a reliable and durable system that withstands the demanding conditions of braking operation.
3Quantity of substance
If the wear protection layer ends exactly at the friction surface edge, then material usage is optimized, but the interface becomes vulnerable to crevice corrosion from dripping water
Solution Approach 1:
The wear protection layer is applied with different coverage in different regions: it covers the entire friction surface where wear resistance is needed, extends into the angled region to seal the interface, and continues onto the vertical side surface to protect against crevice corrosion from dripping water. This localized variation in coverage optimizes both material usage and protective function.
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 extends the service life of brake discs by reducing corrosion susceptibility and wear, maintaining adhesion, and preventing delamination, thus enhancing durability and reducing maintenance frequency.
Implementation Method 1
a wear protection layer is welded to the friction section as a friction surface by laser deposition welding
Implementation Method 2
applying a wear protection layer at least in the region of the friction surface by laser deposition welding
Data Source
Figure 1
Figure 2~4
Figure 5~7
AI summary
A brake disc (1) for a friction brake of a motor vehicle comprises a friction section (6) with at least one friction surface (3a) and a mounting section (7) for attachment to the vehicle. The friction section (6) and the mounting section (7) are formed on a base body (2) made of gray cast iron or steel, and a wear-resistant layer (3) is welded onto the base body (2) as the friction surface (3a) of the friction section (6). The wear-resistant layer (3) on the base body (3) extends beyond the friction surface (3a) into a region (3b) angled relative to the friction surface (3a), where it terminates. In the angled region (3b) of the base body (2), the wear-resistant layer (3) is applied completely and without gaps. Surface sections outside the friction surface (3a) may be provided with a corrosion protection layer (8) that overlaps the wear-resistant layer (3) in the angled region (3b).