Duplex-Coated Brake Disk for Wear, Corrosion, and Dust Reduction
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Solution Overview
Problem
Conventional gray cast iron brake disks suffer from limited wear resistance, increased wear due to abrasive brake linings, poor corrosion resistance, and high dust emissions, leading to brake judder and visual soiling, with existing coatings providing temporary protection that wears off quickly.
Innovation Solution
A low-cost coating system using a duplex steel anti-corrosion layer with high-speed laser deposition welding and a SiC or iron-based anti-abrasion layer applied via thermal spraying, which provides durable corrosion and wear resistance without the use of sensitive or expensive materials like tungsten and nickel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gray cast iron material is used for brake disks, then good thermal conductivity is achieved, but wear resistance deteriorates
Solution Approach 1:
The patent applies a composite material solution by coating the gray cast iron brake disk with a ceramic-based coating layer. The gray cast iron provides excellent thermal conductivity due to its graphite flake structure, while the ceramic coating (containing materials like Al2O3, SiO2, and other oxides) provides high wear resistance and hardness. This composite structure allows the brake disk to simultaneously achieve good heat dissipation and enhanced wear resistance, resolving the contradiction between thermal conductivity and wear resistance.
2Reliability
If conventional coatings are applied to brake disks, then temporary corrosion and wear protection is provided, but the coating wears away quickly
Solution Approach 1:
The patent employs parameter changes in the coating application process, specifically using plasma spray technology to deposit the ceramic coating at controlled temperatures and velocities. The coating parameters (thickness, composition, spray distance, powder feed rate) are optimized to create a dense, well-adhered coating layer. Additionally, the coating is applied after the brake disk undergoes specific heat treatment and surface preparation, ensuring maximum adhesion and long-term durability that resists wear and corrosion throughout the service life of the brake disk.
3Reliability
If abrasive brake linings are used, then stable friction coefficients in wide temperature range are achieved, but brake disk wear increases
Solution Approach 1:
The patent converts the harmful abrasive action of brake linings into a beneficial effect by designing a ceramic coating that is specifically engineered to interact with abrasive particles. The coating contains hard ceramic phases that are more resistant to abrasion than the brake lining materials themselves. When abrasive particles from the lining contact the brake disk surface, they preferentially wear the lining material while the ceramic coating remains intact, effectively converting the abrasive action into a self-sharpening mechanism that maintains friction stability while protecting the brake disk substrate.
4Object-generated harmful factors
If gray cast iron brake disks are exposed to rain, then corrosion resistance is poor, but mechanical stress removal provides clean surface
Solution Approach 1:
The patent applies a preventive ceramic coating to the brake disk surface before corrosion can occur. This preliminary protective layer acts as a barrier between the gray cast iron substrate and moisture in the environment, preventing rust formation entirely. The coating is applied during manufacturing and provides long-term corrosion protection, eliminating the need for subsequent mechanical stress or abrasion to remove rust and maintain surface cleanliness. This preliminary protective action resolves the contradiction by preventing the harmful effect before it manifests.
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 wear and corrosion of brake disks, maintaining performance and appearance over extended periods without the need for frequent re-coating, while minimizing dust emissions and avoiding the use of hazardous materials.
Implementation Method 1
an anti-corrosion layer which is produced from a duplex steel... The anti-corrosion layer is applied to the axial friction side by laser deposition welding
Implementation Method 2
an anti-abrasion layer which is applied to the anti-corrosion layer... applying the anti-abrasion layer to the anti-corrosion layer
Data Source
AI summary
A brake disk for a wheel brake of a land vehicle includes a main body formed from gray cast iron. The main body has at least one axial friction side, at least one anti-corrosion layer applied to the axial friction side, and at least one anti-abrasion layer applied to the anti-corrosion layer. The anti-corrosion layer is a duplex steel layer that provides a cost-effective coating for the brake disk and enables improved corrosion resistance. The anti-abrasion layer is wear resistant and is provided by a SiC material containing at least one oxidic or metallic binder, or by an iron-based alloy having a vanadium carbide reinforcement, a niobium carbide reinforcement, a boron carbide reinforcement, a chromium carbide reinforcement or combinations thereof.