Brake Disc Hardness Gradient Coating for Wear and Crack Resistance
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Solution Overview
Problem
Existing friction brake bodies for motor vehicles suffer from reduced crack resistance and wear due to thermomechanical stresses during braking, leading to potential cracks propagating from the frictional contact surface into the main part, compromising mechanical strength and corrosion resistance.
Innovation Solution
A wear protection layer with increasing hardness from the main part to the frictional contact surface, formed in multiple layers with varying carbide-forming elements and carbon content, including vanadium, titanium, and/or chromium, to prevent crack propagation and enhance wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a wear protection layer is applied to increase hardness and wear resistance, then wear resistance is improved, but crack resistance deteriorates due to brittleness
Solution Approach 1:
The patent applies a gradient hardening profile where the wear protection layer transitions from softer near the substrate to harder at the frictional contact surface. This local variation in material properties allows the surface to provide wear resistance while the softer underlying layers maintain ductility and prevent crack propagation into the main part.
Solution Approach 2:
The patent changes the physical parameter of hardness continuously or incrementally through the wear protection layer thickness. By controlling the degree of hardness to increase from the main part toward the frictional contact surface, the solution optimizes both wear resistance at the surface and crack resistance through the gradient structure.
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 increases crack resistance and wear resistance, preventing cracks from forming in the main part and maintaining friction coefficient during braking, while improving mechanical strength and corrosion resistance.
Implementation Method 1
A coated brake disc with which a wear protection layer with embedded ceramic particles is produced by means of laser deposition welding is known from published patent application EP 3 034 902 A1
Data Source
AI summary
A friction brake body, in particular a brake disc, for a friction brake of a motor vehicle is disclosed. The friction brake body has a main part with at least one wear protection layer on at least one frictional contact region of the main part. The wear protection layer forms a frictional contact surface on the wear protection layer face facing away from the main part. The degree of hardness of the wear protection layer increases incrementally or continuously from the main part to the frictional contact surface.