Laser-Alloyed Brake Disc Surface for Wear and Corrosion Resistance
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Solution Overview
Problem
Friction brakes in motor vehicles experience significant wear and corrosion due to the frictional contact between the brake disc and brake pad, leading to brake dust and reduced performance.
Innovation Solution
A laser-alloyed or laser-dispersed antiwear surface layer is applied to the gray cast iron brake disc using additives like carbides and elemental chromium, which forms a compact, abrasion-resistant layer with enhanced corrosion protection by melting and distributing the additives within the surface layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional friction brake element made of gray cast iron is used, then the manufacturing cost is low and the ease of manufacture is high, but the abrasion resistance is poor and wear occurs significantly
Solution Approach 1:
The patent applies a composite material structure by combining gray cast iron base material with a laser-alloyed surface layer containing carbide-forming elements. This creates a multi-layer composite where the base material provides structural integrity and the surface layer provides enhanced abrasion resistance, resolving the contradiction between manufacturing simplicity and wear resistance.
Solution Approach 2:
The patent changes the chemical composition parameters of the surface layer by introducing carbide-forming elements (chromium, titanium, niobium, vanadium, tungsten, or molybdenum) into the gray cast iron matrix through laser alloying. This parameter modification enhances the surface properties for abrasion resistance while maintaining the overall simplicity of the manufacturing process.
2Duration of action of stationary object
If an antiwear layer based on cemented hard materials or carbides is applied to the brake disc, then the wear resistance is improved, but the manufacturing cost increases and the production process becomes more complex
Solution Approach 1:
The patent replaces traditional mechanical application methods of antiwear layers (such as cladding or coating processes) with laser-based melting and alloying. This substitution enables precise control of the surface layer formation, reduces production complexity, and extends the service life of the brake disc through enhanced wear resistance.
Solution Approach 2:
The patent utilizes the phase transition of the base material and additives during laser processing - the gray cast iron surface and carbide-forming elements are melted and then rapidly solidified to form a homogeneous alloyed surface layer. This phase transition mechanism ensures uniform distribution of carbide-forming elements and creates a durable antiwear surface without complex production steps.
3Strength
If the brake disc is subjected to laser alloying with carbide-forming elements, then the abrasion resistance is significantly increased, but the energy consumption increases
Solution Approach 1:
The patent applies laser alloying only to the friction surface of the brake disc rather than the entire component. This localized treatment concentrates the energy input only where wear resistance is needed, significantly reducing overall energy consumption while achieving the desired surface hardness and abrasion resistance in the contact region.
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 the brake disc, providing increased abrasion resistance and environmental benefits through reduced brake dust emission and lower production costs.
Implementation Method 1
the antiwear layer is a laser-alloyed or laser-dispersed surface layer of the main element, which is made of gray cast iron, with at least one additive. The antiwear layer is thus an surface layer of the gray cast iron main element which has been melted by laser irradiation
Implementation Method 2
After introduction of the additives into the melt, at least substantial melting of the additives and substantial homogeneous distribution in the melt bath occur
Implementation Method 3
During solidification of the at least one carbide-forming element alloyed in in addition to chromium forms metal carbides with the carbon present in the melt, thus reducing the content of free carbon in the surface layer
Implementation Method 4
the chromium remains substantially undissolved after solidification in the iron matrix of the laser-alloyed surface layer and thus forms a passive layer on the surface in the presence of oxygen, offering effective corrosion protection
Implementation Method 5
solidification and cooling occurs in the surface layer in the laser alloying or laser dispersion sufficiently quickly that a martensitic basic microstructure is formed in the surface layer immediately after laser alloying or laser dispersion, thus increasing abrasion resistance
Data Source
AI summary
The disclosure relates to a friction brake body for a friction brake of a motor vehicle, in particular a brake disc, wherein the friction brake body comprises a base body made from gray cast iron, and at least one wear resistant layer formed at least in areas on the base body. The wear resistant layer is a laser alloyed or laser dispersed edge layer of the base body and comprises at least one additive.