Layered Brake Element Coating for Wear and Corrosion Resistance
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Solution Overview
Problem
Existing brake elements for motor vehicles, typically made from gray cast iron, suffer from high weight, corrosion, and wear, leading to premature replacement and increased particulate emissions.
Innovation Solution
A brake element with a base body coated by two build-up layers: a first layer made of an iron alloy alloyed with molybdenum, and a second layer composed of an iron alloy matrix with intercalated tungsten or titanium carbide particles, optimized for wear resistance and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gray cast iron is used for brake elements, then high volumetric heat capacity and thermal shock resistance are achieved, but weight increases and corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining gray cast iron base body with metallic alloy coatings containing ceramic or hard metal particles. This composite structure maintains the thermal properties of gray cast iron while adding wear resistance and corrosion protection from the coating layers, resolving the contradiction between thermal performance and material durability.
2Temperature
If gray cast iron is used for brake elements, then thermal shock resistance is improved, but corrosion resistance worsens
Solution Approach 1:
The patent uses composite metallic alloy coatings with ceramic or hard metal particles embedded in a metallic matrix. This composite structure provides both corrosion protection from the metallic alloy coating and maintains the thermal shock resistance of the gray cast iron base, eliminating the need to choose between these properties.
Solution Approach 2:
The patent applies coating only to the friction surfaces of the brake element where wear and corrosion occur most intensely. This localized application provides corrosion protection exactly where needed while preserving the thermal properties of the gray cast iron throughout the entire component.
3Reliability
If conventional single-layer coatings are applied, then corrosion protection is achieved, but wear resistance and cracking tendency are insufficient
Solution Approach 1:
The patent divides the protective coating into multiple distinct layers: a base metallic alloy coating providing corrosion protection, and additional layers containing ceramic or hard metal particles for wear resistance. This segmented multi-layer structure addresses both corrosion protection and wear resistance requirements that a single-layer coating cannot satisfy.
Solution Approach 2:
The patent employs composite materials in the coating structure, combining metallic alloys with ceramic or hard metal particles in separate layers. This composite approach allows each layer to perform its specialized function - corrosion protection from the metallic base layer and wear resistance from the ceramic/hard metal layers.
4Reliability
If brake element material corrodes, then appearance deteriorates and structural integrity is compromised, but premature replacement increases waste
Solution Approach 1:
The patent applies corrosion-resistant metallic alloy coatings with ceramic or hard metal particles to protect the gray cast iron base body from corrosion. This protective composite coating prevents structural degradation and maintains appearance, thereby extending service life and reducing premature replacement and material waste.
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 the tendency for wear and cracking, enhances corrosion protection, and minimizes particulate emissions, thereby extending the lifespan of the brake element and improving its operational performance.
Implementation Method 1
The coating takes place using thermal spraying processes to apply oxide ceramic coatings or coatings containing hard materials
Implementation Method 2
A first build-up layer is present that adjoins the base body and is made of an iron alloy that is alloyed with molybdenum
Implementation Method 3
the second build-up layer being made of a composite of an iron alloy matrix with intercalated tungsten carbide particles or with intercalated titanium carbide particles
Data Source
AI summary
A brake element for a motor vehicle, having a base body that is planar at least in areas, to the planar sides of which at least two build-up layers are applied in each case, at least in areas. The build-up layers form a surface which, in the mounted state of the brake element on the motor vehicle, is used as a friction surface for a brake pad. A first build-up layer is present that adjoins the base body, and a second build-up layer is applied to the first build-up layer. The second build-up layer is made of a composite of an iron alloy matrix with intercalated tungsten carbide particles or with intercalated titanium carbide particles. At least the first build-up layer is an iron alloy that is alloyed at least with molybdenum in a range of 3 to 20 weight percent.