Titanium Brake Disc Coating for Wear-Resistant Braking Bands
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Solution Overview
Problem
Existing brake discs made of gray cast iron or steel suffer from excessive weight, wear, corrosion, and surface oxidation, with protective coatings detaching easily, making them unsuitable for high-performance braking systems.
Innovation Solution
A brake disc made of titanium or titanium alloy with ceramic and metal particle coatings, including tungsten carbide, iron, and chromium, applied via high-velocity deposition techniques, providing a protective base coating to enhance adhesion and corrosion resistance.
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 microbubbles and poor adhesion
Solution Approach 1:
The patent applies a composite coating system consisting of multiple layers (adhesion layer, intermediate layer, and protective layer) with different material compositions. The adhesion layer contains metal particles that bond to the substrate, the intermediate layer provides transition, and the protective layer offers wear and corrosion resistance. This multi-layer composite structure resolves the adhesion problem by creating gradual transitions in material properties and eliminating microbubbles through controlled deposition.
Solution Approach 2:
The patent introduces an adhesion layer as an intermediary between the metal substrate and the protective coating. This adhesion layer contains metal particles that facilitate bonding between the substrate and subsequent coating layers, acting as a mediator that eliminates poor adhesion and prevents coating detachment caused by microbubbles.
2Strength
If traditional protective coatings are applied to brake discs, then wear resistance is improved, but the coatings flake and detach over time
Solution Approach 1:
The patent employs a composite coating structure with multiple functional layers. The protective layer provides wear resistance through hard particles, while the underlying adhesion and intermediate layers ensure long-term durability by preventing detachment. This composite approach allows the coating to maintain both high wear resistance and extended service life without flaking.
Solution Approach 2:
The patent applies different material compositions and properties to different layers of the coating system. The adhesion layer is optimized for bonding, the intermediate layer for transition and stress distribution, and the protective layer for wear and corrosion resistance. This local optimization of material properties throughout the coating structure ensures both immediate wear protection and long-term durability.
3Reliability
If gray cast iron or steel is used for brake discs, then good braking performance is achieved, but weight and corrosion are excessive
Solution Approach 1:
The patent uses a composite structure where a metal substrate (gray cast iron or steel) provides the mechanical strength and braking performance, while a protective coating system provides corrosion resistance and surface protection. This composite approach allows the use of heavier metal materials while compensating for their drawbacks through the protective coating, effectively managing the weight-performance-corrosion resistance trade-off.
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 offers improved resistance to wear and corrosion, reduced weight, and enhanced mechanical strength, ensuring the coating does not detach, while maintaining mechanical integrity and thermal stability, thus suitable for high-performance braking systems.
Implementation Method 1
directly depositing a material in particulate form consisting of ceramic and metal particles above at least the upper face (20a) and/or lower face (20b) so to create an upper coating layer (3) and/or lower coating layer (3')
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for manufacturing a braking band (2) for a brake disc (1) of a disc brake comprises the following operating steps: • a) providing a braking band (2) provided with a base band (20) having an upper face (20a) and a lower face (20b) arranged on the opposite side to, i.e. opposed to, the upper face (20a), the lower face and upper face each defining, at least in part, one of the two sides of the brake disc (1), the base band (20) being made of titanium or titanium alloy; • b) directly depositing a material in particulate form consisting of ceramic and metal and/or intermetallic particles above at least the upper face (20a) and/or the lower face (20b) so to create an upper coating layer (3) and/or lower coating layer (31) suitable for withstanding the braking action of the calipers of a disc brake.