Laser-Clad Brake Disc Edge Protection Against Wear Delamination
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Solution Overview
Problem
Conventional brake discs made of gray cast iron suffer from high wear and corrosion, leading to premature failure, especially at the edge of the friction surface, due to the delamination of anti-wear layers and exposure to the environment.
Innovation Solution
The anti-wear layer is extended beyond the friction surface into an angled region, ensuring full coverage and continuous bonding with the base body, and optionally combined with an anti-corrosion layer, using laser deposition welding to enhance adhesion and protect against corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an anti-wear layer is applied to the friction surface of a brake disc, then wear resistance is improved, but the anti-wear layer is prone to delamination at the edge of the friction surface, reducing reliability
Solution Approach 1:
The anti-wear layer is extended from the friction surface into the angled region, adding a spatial dimension to the coverage. This extension into the angled region creates an overlapping area that prevents delamination by distributing stresses and eliminating sharp edges where delamination typically initiates.
2Reliability
If the anti-wear layer is extended into the angled region, then coverage and adhesion are improved, but manufacturing complexity increases
Solution Approach 1:
The angled region is prepared in advance during brake disc manufacturing, creating a pre-formed geometry that facilitates subsequent anti-wear layer application. This preliminary structuring allows the anti-wear layer to be applied continuously from the friction surface into the angled region without requiring complex additional manufacturing steps.
3Ease of manufacture
If conventional anti-wear layer application is used, then manufacturing is simpler, but the edge of the friction surface is exposed to corrosion, reducing durability
Solution Approach 1:
By extending the anti-wear layer into the angled region, the protection is extended beyond the traditional friction surface boundary. This dimensional extension creates an overlapping coverage area that shields the edge regions from corrosive environments while maintaining a manageable manufacturing process.
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
This configuration significantly prolongs the service life of the brake disc by reducing corrosion susceptibility and maintaining the integrity of the anti-wear layer, preventing delamination and wear, thus enhancing durability and stability.
Implementation Method 1
an anti-wear layer is applied to the friction portion as the friction surface by laser deposition welding
Implementation Method 2
The anti-wear layer and the base body are melted by a laser beam and are bonded to one another in a substance-to-substance bonding
Data Source
AI summary
A brake disc for a friction brake of a transportation vehicle includes a friction portion having at least one friction surface and a fastening portion for fastening to the transportation vehicle, wherein the friction portion and the fastening portion are formed on a base body of gray cast iron or steel, and an anti-wear layer is applied to the friction portion as the friction surface by laser deposition welding. The anti-wear layer on the base body is continued beyond the friction surface into a region that is angled relative to the friction surface, and ends in that region, and is applied in the angled region of the base body with full coverage and without any gaps to the base body. Surface portions outside of the friction surface are provided with an anti-corrosion layer which overlaps the anti-wear layer in the angled region.