Diffusion-Alloy Brake Carrier Body for Wear and Corrosion Resistance
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Solution Overview
Problem
Conventional brake disks suffer from rapid wear and corrosion, especially in vehicles that infrequently use traditional braking systems, leading to reduced service life and potential safety hazards.
Innovation Solution
A brake element carrier body with a metallic base body partially or completely coated with an alloy that is diffused into the base body, creating a diffusion zone with improved tribological properties and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional painting or superficial spraying is used for corrosion protection, then corrosion resistance is improved initially, but wear resistance deteriorates quickly due to low tribological quality
Solution Approach 1:
The invention changes the material parameters by using an alloy that can diffuse into the base material, transforming from a superficial coating to a diffusion-bonded layer. This creates a gradient structure where the alloy concentration decreases with depth, providing both corrosion resistance at the surface and wear resistance through the diffusion zone.
Solution Approach 2:
The invention creates a composite structure consisting of the metallic base body and the diffused alloy layer. This composite material system combines the corrosion resistance of the alloy with the mechanical properties of the base material, achieving both protection functions simultaneously.
2Object-affected harmful factors
If a corrosion protection layer is applied, then corrosion resistance is improved, but friction and wear increase due to low tribological quality of conventional coatings
Solution Approach 1:
The invention modifies the surface parameters by creating a diffusion zone with altered material properties. The alloy diffusion changes the surface composition and structure, providing both corrosion resistance and improved tribological characteristics compared to conventional coatings.
3Use of energy by moving object
If traditional braking systems are used infrequently, then energy consumption is reduced, but corrosion protection deteriorates due to lack of friction-based corrosion removal
Solution Approach 1:
The invention performs preliminary corrosion protection by applying the alloy coating before any corrosion can occur. This pre-applied protective layer eliminates the need for friction-based corrosion removal that would require traditional braking operations, allowing infrequent braking without compromising corrosion protection.
4Object-affected harmful factors
If a thick corrosion protection layer is applied, then corrosion resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The invention changes the manufacturing approach from applying thick superficial coatings to creating a diffusion-bonded layer. The diffusion process naturally creates a gradient concentration profile, eliminating the need for thick uniform coatings and simplifying the manufacturing process while maintaining effective 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 diffusion zone enhances wear resistance and corrosion protection, extending the service life of brake disks and ensuring reliable braking performance even in vehicles with low traditional braking usage.
Implementation Method 1
Diffusion is generally understood as the equalization of a concentration difference between several substances until an equilibrium is reached. Diffusion can be a thermally activated equalization process of a concentration difference in a solid, liquid or gas without external influence.
Data Source
AI summary
A brake element carrier body with a metallic base body is claimed, wherein a surface of the base body is at least partially, preferentially completely, coated with an alloy, wherein the alloy has diffused into the base body in a diffusion zone.