Spiral Brake Disk Surface Structure for Shadow-Free Coating Adhesion
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Solution Overview
Problem
Existing brake disk surface structuring methods result in shadowing effects during coating, reducing adhesion, particularly in processes like plasma vaporization and thermal spraying.
Innovation Solution
A brake disk with a spiral-shaped trench having a first recess wall that undercuts and a second non-undercutting wall, where the width decreases with increasing depth, ensuring full coating access and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the surface is roughened by making recesses with increasing width as depth increases to create positive connection, then coating adhesion is improved, but shadowing effects occur during coating reducing coating thickness and adhesion
Solution Approach 1:
The recess is designed with asymmetric walls: one wall is vertical or slightly inclined providing undercut for mechanical anchoring, while the other wall is inclined at a smaller angle to prevent shadowing. This asymmetric geometry allows simultaneous achievement of strong adhesion through undercut and uniform coating through open geometry.
Solution Approach 2:
Different regions of the recess structure serve different functions: the undercut region provides mechanical anchoring for adhesion, while the open upper region allows coating particle access. This local differentiation of structural properties optimizes both adhesion and coating uniformity.
2Strength
If recesses are made deeper to enhance positive connection effect, then coating adhesion is improved, but shadowing effects increase dramatically reducing coating thickness
Solution Approach 1:
The asymmetric wall design allows deeper recesses to be created without proportionally increasing shadowing. The vertical wall provides deep undercut for anchoring, while the shallowly inclined opposite wall maintains open geometry for coating access, enabling deeper recesses with better coating coverage.
3Strength
If the recess width increases with depth to create undercut effect, then mechanical anchoring is improved, but coating particle access to the recess walls is reduced
Solution Approach 1:
The recess has asymmetric walls where one wall is vertical providing the undercut effect for mechanical anchoring, while the other wall is inclined at a smaller angle to the perpendicular, maintaining an open geometry that facilitates coating particle access to both walls.
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
Enhances coating adhesion by allowing uniform coating distribution without shadowing, improving the adhesion of coatings on brake disks.
Implementation Method 1
coating processes such as plasma vaporization and deposition from the gas phase (PVD process)
Implementation Method 2
deposition from the gas phase (PVD process)
Implementation Method 3
in which the coating particles fly in a straight line from the material source to the substrate
Data Source
AI summary
A brake disk with a surface which is structured in order to increase the adhesion of a coating on the surface, wherein the structuring of the surface comprises at least one recess, the depth of which decreases as the depth of the recess increases wherein the at least one recess has the shape of a spiral structure.