Titanium Brake Disc Band Coating for Wear and Corrosion Resistance
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Solution Overview
Problem
Traditional brake discs made of gray cast iron or steel suffer from excessive weight, wear, and corrosion, with protective coatings often detaching due to inadequate adhesion, limiting their suitability for high-performance braking systems.
Innovation Solution
A brake disc manufactured with a titanium or titanium alloy base band and ceramic-metal coating layers, specifically tungsten carbide and chromium-aluminum, providing enhanced corrosion resistance and mechanical strength without the need for intermediate adhesion layers, using high-velocity oxygen fuel or kinetic metallization deposition techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective coatings are applied to gray cast iron or steel brake discs, then wear resistance and corrosion resistance are improved, but the coatings detach due to inadequate adhesion
Solution Approach 1:
The patent uses a composite material structure consisting of a gray cast iron base material combined with a ceramic coating layer. This composite structure provides both the mechanical strength of cast iron and the wear/corrosion resistance of ceramic, while the direct bonding interface eliminates the need for intermediate adhesion layers that cause flaking in traditional coatings.
Solution Approach 2:
The patent introduces a specific intermediate treatment layer between the gray cast iron substrate and the ceramic coating. This intermediary layer serves as a bonding interface that enhances adhesion, preventing coating detachment while maintaining the protective functions of the ceramic coating.
2Duration of action of moving object
If traditional protective coatings are used on brake discs, then wear resistance is improved, but the coatings flake and detach over time
Solution Approach 1:
The patent employs a composite material system with a gray cast iron base and ceramic coating, creating a durable structure that maintains coating integrity throughout the service life. The composite design ensures both wear resistance and long-term structural stability without flaking.
Solution Approach 2:
The intermediate treatment layer acts as a stable bonding interface that prevents coating flaking and detachment during extended use. This intermediary structure ensures reliable adhesion throughout the entire service life of the brake disc.
3Ease of manufacture
If gray cast iron or steel is used for brake discs, then cost is reduced, but weight increases excessively
Solution Approach 1:
The patent creates a composite brake disc using gray cast iron for the base structure (maintaining cost-effectiveness and manufacturability) combined with a ceramic coating layer (reducing weight while enhancing performance). This composite approach achieves weight reduction without significantly increasing manufacturing complexity.
4Reliability
If protective coatings are applied to brake discs, then corrosion resistance is improved, but the coating structure becomes more complex with adhesion layers
Solution Approach 1:
The patent introduces a simplified intermediate treatment layer that provides effective adhesion between the gray cast iron substrate and ceramic coating. This single intermediary layer achieves corrosion protection without requiring multiple complex coating layers, thus maintaining reliability while reducing structural complexity.
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 achieves significant resistance to wear and corrosion, prevents coating detachment, and maintains a lightweight design, offering improved mechanical strength and thermal stability comparable to stainless steel, while simplifying the manufacturing process and reducing material costs.
Implementation Method 1
using high-velocity oxygen fuel or kinetic metallization deposition techniques
Implementation Method 2
using high-velocity oxygen fuel or kinetic metallization deposition techniques
Data Source
AI summary
A method for manufacturing a braking band may include providing a braking band with a base band having an upper face and a lower face, where the base band being is made of titanium or titanium alloy. The method may also include directly depositing a material in particulate form consisting of ceramic and metal and/or intermetallic particles above at least the upper face and/or the lower face so to create an upper coating layer and/or lower coating layer. A braking band for a brake disc may have a base band entirely made of titanium alloy and having an upper face and a lower face, an upper coating layer, and a lower coating layer joined to the base band along the lower face. The upper coating layer and the lower coating layer consist of a mixture of ceramic and metal and/or intermetallic particles.