Brake Disc Intermediate Layer for Wear-Resistant Coating Adhesion
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Solution Overview
Problem
Existing friction brake bodies for motor vehicles suffer from wear and corrosion due to the friction contact between the brake block and the brake disc, leading to brake dust and reduced brake performance.
Innovation Solution
A friction brake body with a metallic intermediate layer applied between the wear protection layer and the base body, using laser cladding to enhance adhesion, crack resistance, and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a wear protection layer is applied to the base body, then wear resistance is improved, but adhesion between layers deteriorates
Solution Approach 1:
A metallic intermediate layer is introduced between the wear protection layer and the gray cast iron base body. This intermediate layer acts as a mediator that provides both mechanical anchoring and metallurgical bonding, ensuring strong adhesion while allowing the wear protection layer to maintain its abrasion-resistant properties.
Solution Approach 2:
The brake disc is constructed as a composite structure with three distinct layers: the gray cast iron base body, the metallic intermediate layer, and the wear protection layer. Each layer contributes specific properties, and their combination creates a system that exceeds the sum of individual components in terms of adhesion and wear resistance.
2Reliability
If an intermediate layer is added between the wear protection layer and base body, then adhesion is improved, but device complexity increases
Solution Approach 1:
The intermediate layer's composition and thickness are optimized as key parameters. By controlling the metallurgical parameters during laser cladding (power, speed, material feed rate), the intermediate layer achieves optimal properties for adhesion without requiring excessive thickness or complex multi-layer configurations.
3Manufacturing precision
If laser cladding is used to apply the intermediate layer, then manufacturing precision is improved, but production cost increases
Solution Approach 1:
Traditional mechanical application methods (such as manual spraying or rolling) are replaced with laser cladding technology. This substitution enables precise control of layer thickness and composition, automatic material deposition, and integration with digital manufacturing systems, improving precision while the automation reduces long-term operational costs.
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 improves the adhesion of the wear protection layer, increases crack resistance, and provides effective corrosion protection, thereby reducing wear and brake dust while enhancing brake performance.
Implementation Method 1
The metallic intermediate layer (6) is applied to the base body (3) by laser deposition welding
Implementation Method 2
the wear-resistant layer is applied to the intermediate layer by thermal spraying or laser deposition welding
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a frictional brake element (1) for a friction brake of a motor vehicle, in particular brake disk (2), having a main element (3) which is manufactured in particular from grey cast iron and which has at least one wear protection layer (5) applied to the main element (3) and at least one intermediate layer (6) situated between the wear protection layer (5) and the main element (3). It is provided that the intermediate layer (6) is a metallic intermediate layer (6) applied by laser deposition welding.