High-Entropy Brake Disc Coating for Wear and Corrosion Resistance
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Solution Overview
Problem
Existing brake disc materials, primarily gray cast iron, suffer from low hardness, limited wear resistance, susceptibility to oxidation and rust, poor thermal fatigue resistance, and inadequate performance under varying operating conditions, necessitating an upgrade for improved abrasion and corrosion resistance.
Innovation Solution
A high-entropy alloy powder with a specific molar ratio of Al, Co, Ni, Cu, and Ti, combined with a multi-gradient coating structure, is prepared using gas atomization and atmospheric plasma spraying to enhance bonding and provide superior wear and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If gray cast iron is used for brake discs, then cost is low and strength is high, but hardness is low (about 200 HV) and wear resistance is limited
Solution Approach 1:
The patent applies composite materials by combining gray cast iron substrate with high-entropy alloy coating (Al-Co-Ni-Cu-Ti system). The coating layer with superior wear resistance properties is deposited on the brake disc surface, creating a composite structure that leverages the strength of the substrate and the wear resistance of the coating, thereby resolving the contradiction between strength and wear resistance.
2Duration of action of stationary object
If gray cast iron is used for brake discs, then it is durable and prevents softening under frictional heat, but susceptibility to oxidation and rust is poor
Solution Approach 1:
The high-entropy alloy coating serves as a protective barrier layer in the composite structure. This coating layer has excellent corrosion and oxidation resistance properties, protecting the underlying gray cast iron substrate from harmful environmental factors while maintaining the substrate's durability and heat resistance characteristics.
3Ease of manufacture
If traditional metal materials are used for brake discs, then manufacturing is simple, but braking and wear resistance is inadequate under various operating conditions
Solution Approach 1:
The patent creates a composite brake disc consisting of a conventional gray cast iron body (easy to manufacture) and a high-entropy alloy coating layer (superior braking and wear resistance). This composite approach allows the bulk material to remain simple and cost-effective while the surface coating provides enhanced performance under various operating conditions.
4Reliability
If copper-nickel-tin alloy coating is applied on stainless steel substrate, then wear resistance is better than alloy block, but wear rate is still higher compared to high-entropy alloy coating
Solution Approach 1:
The patent changes the material parameters by transitioning from conventional Cu-Ni-Sn alloy coating to a high-entropy alloy coating system (Al-Co-Ni-Cu-Ti). This parameter change in composition and structure results in significantly reduced wear rate and improved wear resistance, as the high-entropy alloy forms a more stable and durable protective layer under frictional conditions.
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 high-entropy alloy powder forms a dense, uniform coating with high hardness and excellent abrasion and corrosion resistance, addressing the limitations of traditional brake disc materials.
Implementation Method 1
atmospheric plasma spraying
Implementation Method 2
gas atomization
Data Source
AI summary
The present disclosure provides a brake disc coating and a method for preparing the brake disc coating. The brake disc coating is prepared from a high-entropy alloy powder, a preparation material of the high-entropy alloy powder includes an Al powder, a Co powder, a Ni powder, a Cu powder, and a Ti powder, a molar ratio of metal elements Al, Co, Ni, Cu, and Ti in the high-entropy alloy powder is in a range of 1:1:1:1:(1.1-1.3), and the high-entropy alloy powder has a single body-centered cubic (BCC) crystal structure.