Laser-Alloyed Gray Cast Iron Brake Disc for Low-Wear Braking
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Solution Overview
Problem
Friction brakes for motor vehicles experience significant wear and corrosion due to abrasion between the brake pad and disc, leading to brake dust and reduced performance, which existing wear protection methods have not adequately addressed.
Innovation Solution
A laser-alloyed edge layer is applied to a gray cast iron brake disc using additives like chromium carbide, niobium carbide, and elemental chromium, which forms a cohesive, corrosion-resistant wear protection layer with enhanced abrasion resistance through melting and alloying, followed by rapid solidification and potential additional hardening processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wear protection layer is applied to the friction brake body, then wear and corrosion resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple functions into a single laser processing step: melting the base material, mixing with additives, and forming the wear protection layer all occur in one continuous laser alloying process, eliminating separate coating and bonding steps
Solution Approach 2:
The patent replaces traditional mechanical coating methods (such as plasma spraying or thermal spraying followed by bonding) with a laser-based metallurgical process that directly fuses the wear protection layer into the base material through laser alloying
2Reliability
If traditional coating methods are used to protect the brake disc, then wear resistance is improved, but brake dust emissions increase
Solution Approach 1:
The patent creates a composite material structure by incorporating ceramic particles (such as aluminum oxide, silicon carbide, or boron carbide) into the metal matrix during laser alloying, forming a metallurgically bonded composite that reduces wear and brake dust
Solution Approach 2:
The patent converts the harmful effect of friction and abrasion into a beneficial process by using the laser's thermal energy to melt and fuse materials, creating a wear-resistant surface that actually reduces future abrasion and brake dust generation during normal brake operation
3Reliability
If the surface layer is melted and alloyed with additives, then abrasion resistance is improved, but energy consumption increases
Solution Approach 1:
The patent applies laser energy locally only to the surface layer where wear protection is needed, rather than heating the entire brake disc, concentrating energy input precisely where it is required to melt and alloy the surface
Solution Approach 2:
The laser processing is applied periodically only during manufacturing, not during continuous brake operation, and the rapid solidification of the melted layer occurs quickly, limiting the duration of high energy input
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 on the friction brake body, minimizing brake dust emissions and providing improved abrasion and corrosion resistance while maintaining cost-effectiveness and environmental benefits.
Implementation Method 1
The surface layer of the base body is melted into a melt using laser radiation
Implementation Method 2
The additive is thus added to the molten material of the base body and is distributed there as a result of convective mixing of the melt pool
Implementation Method 3
a sufficiently rapid solidification and cooling in the surface layer during laser alloying or laser dispersing, so that a martensitic basic structure forms in the surface layer immediately after laser alloying or laser dispersing
Implementation Method 4
the chromium remains substitutionally dissolved in the iron matrix of the laser-alloyed surface layer and thus, in the presence of oxygen, forms a passive layer on the surface that offers effective corrosion protection
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a friction brake body (1) for a friction brake of a motor vehicle, in particular a brake disc (2), wherein the friction brake body (1) comprises a base body (3) made from gray cast iron, and at least one wear resistant layer (5) formed at least in areas on the base body (5). According to the invention, the wear resistant layer (5) is a laser alloyed or laser dispersed edge layer (6) of the base body (3) and comprises at least one additional material (9).