Braking Element Friction Surface Joining for Wear and Corrosion Resistance
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Solution Overview
Problem
Conventional braking elements suffer from superficial corrosion protection, which is quickly worn off during initial braking operations, leading to noise issues and reduced braking power, and have high production costs due to inefficient coating methods.
Innovation Solution
A method of producing braking elements by positioning and cohesively bonding a metallic semifinished product layer on the friction surface of a metallic main body using joining methods like magnetic pulse welding, creating a thick, durable friction surface with improved antiwear and anticorrosion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating methods (thermal spraying) are used to protect braking elements from corrosion and wear, then the friction surface receives protective coating, but the coating is rubbed away immediately after first braking operations, leading to quick corrosion of base material
Solution Approach 1:
The invention changes the bonding method parameter from thermal spraying to cohesive bonding techniques (such as diffusion bonding, metallurgical bonding, or mechanical interlocking), fundamentally altering how the coating adheres to the substrate. This parameter change enables the coating to withstand braking operations without being rubbed away, directly resolving the durability issue.
Solution Approach 2:
The invention creates a composite structure where the protective coating and metallic main body are cohesively bonded to form an integrated material system. This composite approach combines the corrosion resistance of the coating with the structural integrity of the base material, ensuring long-term protection while maintaining mechanical performance.
2Reliability
If thick protective layers are applied to friction surfaces, then wear and corrosion protection is improved, but production costs increase due to material and processing requirements
Solution Approach 1:
The invention applies the protective layer in advance during the manufacturing process through cohesive bonding, creating a permanently integrated structure. This preliminary action eliminates the need for subsequent re-coating or maintenance, reducing long-term production costs while ensuring durable protection from the outset.
Solution Approach 2:
The cohesively bonded protective layer serves itself by maintaining permanent adhesion to the substrate without requiring external reinforcement or maintenance. The integrated structure automatically resists wear and corrosion throughout its service life, eliminating the need for additional protective measures or frequent replacements.
3Reliability
If short-term corrosion protection is applied to braking elements, then protection from corrosion is provided until brake system is put to use, but protection is only temporary and does not prevent long-term corrosion
Solution Approach 1:
The invention fundamentally changes the protection duration parameter from short-term to permanent by implementing cohesive bonding. This parameter transformation ensures the protective layer remains intact throughout the entire service life of the braking element, eliminating the need for periodic re-protection and providing continuous corrosion resistance.
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 provides long-lasting wear and corrosion protection, reducing noise issues and material costs while enhancing thermal conduction and bonding strength, resulting in a longer service life for braking elements.
Implementation Method 1
positioning and cohesively bonding a metallic semifinished product layer on the friction surface of a metallic main body using joining methods like magnetic pulse welding
Data Source
AI summary
The present invention relates to the field of automotive engineering and industrial plant engineering and concerns a method for producing braking elements and braking elements produced in this manner. The problem according to the invention consists in specifying a method and a braking element having improved wear and corrosion protection and a larger layer thickness of the frictional surface and which can be produced time- and cost-effectively. The problem is solved by a braking element which has at least one metallic main element having a frictional surface applied on a formed surface region, which frictional surface is a prefabricated layer of a metallic semi-finished product which is integrally connected to the metallic main element by means of a joining technique. The problem is also solved by a method in which the frictional surface is formed by at least one layer of a metallic semi-finished product and same is integrally connected to the metallic main element by means of a joining technique. The braking elements according to the invention can be used for example in vehicles, industrial plant or wind turbines.