Brake Disc Laser Cladding With Differential Powder Melting
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Solution Overview
Problem
Existing methods for producing wear protection layers on friction brake bodies using laser cladding lack optimal control over the melting and mixing of multiple powdered additives, leading to suboptimal bonding and potential detachment during thermomechanical stress.
Innovation Solution
The method involves separately feeding at least two powdered additives into the laser cladding process, controlling their dwell times by varying angles and distances from the laser beam, ensuring selective melting and uniform mixing to enhance the substance-to-substance bond with the base body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple powdered additives are fed as a mixture during laser cladding, then the process is simple, but the additives cannot be individually controlled for optimal melting and bonding
Solution Approach 1:
The patent divides the additive delivery system into separate channels, with each powdered additive being fed through its own nozzle independently. This segmentation allows each additive to be controlled separately in terms of feed rate, particle size distribution, and timing of introduction into the laser beam, enabling precise control over melting and bonding characteristics while maintaining process simplicity through modular architecture.
2Device complexity
If additives are blown at the same angle and distance from the laser beam, then the setup is simple, but the dwell times in the laser beam are identical limiting selective melting control
Solution Approach 1:
The patent implements local quality by allowing each nozzle to be positioned at different angles and distances from the laser beam path. This enables each additive to experience a locally optimized dwell time in the laser beam according to its specific melting requirements, particle characteristics, and desired bonding behavior, while the overall system maintains a relatively simple geometric configuration.
3Temperature
If the laser beam power is increased to ensure complete melting of all additives, then melting is improved, but excessive melting or dissociation of certain additives occurs
Solution Approach 1:
The patent applies partial action by allowing different additives to receive different degrees of laser energy exposure through controlled dwell times. Additives with lower melting points or higher susceptibility to dissociation are exposed to the laser beam for shorter durations or at lower power densities, while additives requiring more energy receive correspondingly higher exposure, thereby achieving complete melting without excessive heating or dissociation.
4Reliability
If additives are fed separately with different dwell times, then optimal bonding is achieved, but the process complexity increases
Solution Approach 1:
The patent merges multiple separate additive feeding operations into a single integrated laser cladding process. By synchronizing the independent nozzle systems to operate simultaneously during one continuous laser beam pass, the process achieves optimal bonding reliability through controlled differential dwell times while avoiding the complexity of multiple sequential processing steps.
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 approach results in a wear protection layer with improved adhesion, reduced detachment, and enhanced properties such as corrosion and wear resistance, particularly when using iron-based alloys and hard materials like carbides.
Implementation Method 1
the surface of the base body to be coated is melted locally by means of a laser beam, and a powdered additive is added. Before reaching the molten surface, the additive is at least partially liquefied or completely melted by the laser beam
Implementation Method 2
the surface of the base body to be coated is melted locally by means of a laser beam
Implementation Method 3
each of the additives is blown by at least one nozzle each onto the base body such that it enters the laser beam before reaching the base body
Data Source
AI summary
A method is disclosed for producing a friction brake body, in particular a brake disc, which has a main part with a frictional contact region. A wear protection layer is produced on the frictional contact region by way of laser cladding using a laser beam oriented towards the frictional contact region. The wear protection layer is produced by at least one pulverulent additive during the laser cladding. At least two pulverulent additives are added simultaneously such that the dwell time thereof in the laser beam differs.