Amorphous Alloy Brake Rotor Coating for Low Dust and Corrosion Resistance
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Solution Overview
Problem
Existing brake devices face challenges with corrosion, wear, and thermal distortion, leading to reduced performance and safety, particularly in vehicles where conventional cast iron brake discs are heavy and prone to corrosion.
Innovation Solution
A brake body with a rotor coated in an amorphous alloy layer, which has a thermal expansion coefficient matching that of the rotor, providing improved corrosion and wear resistance, reduced dust generation, and extended lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cast iron brake discs are used, then manufacturing cost is low and manufacturing process is simple, but the brake discs are heavy and prone to corrosion
Solution Approach 1:
The patent applies composite materials by combining aluminum alloy (lightweight base material) with a ceramic coating layer (corrosion-resistant surface layer). This creates a composite structure that leverages the advantages of both materials: the aluminum alloy provides low weight while the ceramic coating provides corrosion and wear resistance, effectively resolving the contradiction between weight reduction and corrosion protection.
2Reliability
If heat treatment processes (e.g., ferritic-nitro carburizing) are used to improve surface characteristics, then corrosion and oxidation resistance is improved, but thermal distortion occurs affecting dimensional stability
Solution Approach 1:
The patent replaces the conventional heat treatment process (ferritic-nitro carburizing) with a ceramic coating process. Instead of using thermal fields that cause overall heating and potential distortion, the invention applies a ceramic coating layer that provides oxidation and corrosion resistance without subjecting the entire component to high temperatures, thereby avoiding thermal distortion and maintaining dimensional stability.
3Reliability
If diffusion bonding process is used to form aluminum core with stainless steel sheet, then corrosion resistance is improved, but high-pressure rolling is required making it difficult to apply to flat discs
Solution Approach 1:
The patent replaces the diffusion bonding process (which requires high-pressure rolling) with a ceramic coating process. The coating can be applied to flat disc surfaces using conventional coating techniques without requiring high-pressure equipment, making the process much more suitable for flat disc geometries while still achieving corrosion resistance.
4Reliability
If metal spraying method is used to coat brake discs, then corrosion resistance is improved, but separation between metal base and sprayed coating occurs causing peeling
Solution Approach 1:
The patent changes the material parameters by selecting ceramic materials with thermal expansion coefficients matched to the aluminum alloy substrate. This parameter matching prevents thermal stress-induced delamination during temperature cycling, ensuring stable adhesion of the coating layer while providing the desired corrosion protection.
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 amorphous alloy coating layer enhances the brake body's durability, reduces dust and fine dust generation during braking, and extends the lifespan of the brake device while lowering manufacturing costs.
Implementation Method 1
the coating layer includes an amorphous alloy and has a thermal expansion coefficient 1.0 times to 1.4 times a thermal expansion coefficient of the rotor
Data Source
AI summary
A brake body according to the present disclosure has a coating layer which contains an iron-based amorphous alloy and is formed on a contact surface at which a friction means rubs against the brake body to generate braking force which the brake body is rotated. The coating layer has a low friction coefficient and thus generates less dust during braking. The coating layer also has high corrosion resistance and wear resistance and may thus guarantee high performance and good price competitiveness when applied to a brake base material produced at low cost.