Multi-Laser Brake Disc Cladding for Faster Coating and Lower Wear
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Solution Overview
Problem
Existing laser cladding methods for brake discs face challenges with high process times, reduced adhesion due to graphite melting, and increased wear of optical components and nozzles from high-power lasers.
Innovation Solution
The method employs multiple laser and processing heads (LPHs) with lower power levels (less than or equal to 6 kW) simultaneously on the same surface, using an Archimedean spiral pattern to coat brake discs efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-power lasers (over 20 kW) are used for laser cladding, then deposition rates and productivity are improved, but optical components and nozzles experience increased wear and reduced lifetime
Solution Approach 1:
The patent divides the single high-power laser process into multiple parallel low-power laser processes. Specifically, it uses multiple laser and processing heads (LPHs) with lower power levels (≤6 kW each) operating simultaneously on different locations of the brake disc surface. This segmentation allows the system to achieve high overall deposition rates while each individual laser operates at a safe power level that does not damage optical components or nozzles.
2Productivity
If high-power lasers are used for laser cladding, then deposition rates are improved, but thermal deformation of the brake disc increases
Solution Approach 1:
The patent segments the thermal load by using multiple low-power lasers instead of one high-power laser. Each laser head deposits material at a lower power level, distributing the thermal input across multiple locations simultaneously. This prevents excessive localized heating and reduces the risk of brake disc deformation while maintaining high overall productivity through parallel processing.
Solution Approach 2:
The patent transitions from a single-point sequential processing approach to a multi-point parallel processing approach. By deploying multiple LPHs at different radial positions on the brake disc, the system adds a spatial dimension to the processing, allowing simultaneous deposition across multiple zones. This dimensional expansion enables high productivity without concentrating thermal energy in a single location.
3Strength
If graphite particles are melted or evaporated during laser cladding, then adhesion of the coating is improved, but local defects and reduced adhesion occur
Solution Approach 1:
The patent applies local quality by using multiple laser heads with optimized power levels (≤6 kW each) that provide sufficient energy to improve adhesion by partially melting graphite particles without completely vaporizing them. This localized control of thermal input at each processing zone prevents the formation of voids and defects while still achieving adequate adhesion enhancement, unlike single high-power lasers that cause excessive graphite removal.
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
This approach significantly reduces laser cladding process times, enhances coating adhesion, and minimizes wear on optical components and nozzles, while maintaining high process reliability.
Implementation Method 1
laser cladding process
Implementation Method 2
graphite lamellae and/or spherical particles on the surface of the substrate can be melted or even evaporated during the coating process
Implementation Method 3
graphite lamellae and/or spherical particles on the surface of the substrate can be melted or even evaporated during the coating process
Data Source
AI summary
A method to produce a coated brake disc, the method including the steps of:—providing a brake disc with a first and a second friction surface—coating at least part of the first friction surface by a laser cladding process wherein for the laser cladding process more than one, preferably two or especially preferred at least three laser and processing heads are used and at least during part of the laser cladding process the preferably two or especially preferred at least three laser and processing heads are used simultaneously at different locations of the first friction surface.