Application of Laser Cladding on Wear-resistant Layer of Brake Disc

In urban areas, particle pollution can always be serious enough to endanger health. Among them, 25% of the fine particles are emitted from brake disc wear. The new wear-resistant material laser cladding layer can realize the wear-resistant and anti-corrosion coating of automobile brake discs now. This can effectively reduce wear and tear, reduce particle pollution, and can continue to extend the service life of the brake system.

According to the latest research, particles are the most harmful to our health among air pollutants, especially ultrafine particles, such as soot particles, are classified as carcinogens. In addition, fine particles can cause allergies, asthma, respiratory and cardiovascular diseases. Internal combustion engines, especially diesel engines, are recognized by public opinion as the main culprit of urban fine particle pollution. Therefore, countries have been discussing feasible measures to reduce the emission of fine particles from road traffic.

What makes many drivers dissatisfied is that the first regulations are driving bans and speed limits. However, in the current discussion, one thing always seems to be overlooked: diesel engines are only one aspect of the problem, because a large part of the fine particles detected in the city center come from the fine particles produced by wear of car components. Except for tires, these fine particles mainly come from brake discs and brake pads. Even a large-scale switch to electric vehicles cannot change this. Only by controlling brake wear can the fine particle pollution be significantly reduced. Therefore, Germany is expected to make a legal definition of the maximum value of fine particles caused by braking in the middle of 2021. Currently, manufacturers and suppliers are already looking for alternative methods.

The new laser cladding process can reduce wear and corrosion.

The wear-resistant cladding layer is suitable for protecting high-load components from wear. However, wear-resistant cladding layers are almost never used in traditional automobile brake discs. Anti-corrosion cladding has been used for brake discs for some time. In contrast, the wear-resistant cladding layer has so far only been used in niche areas such as high-priced sports cars and luxury cars. For cost reasons, the cladding process used so far is not suitable for industrial mass production.

A technological innovation may change this situation in the future: laser coating technology (also known as cladding) can now be used to achieve a standardized high-strength wear-resistant cladding layer on brake discs, thereby significantly reducing wear and fine particles discharge and extend service life. Compared with the thermal spraying process used in the sports car field, laser cladding is more economical because it saves more materials and energy consumption, and also reduces preparation work.

Therefore, the new method is also suitable for the thin wear-resistant layer cladding of traditional gray cast iron brake discs, which is also affordable for the mass market. The laser cladding layer can also be applied to small or mini-cars. Although the purchase cost of cladding brake discs is slightly higher, the service life is longer, which makes it cost-effective. In addition, the laser cladding layer is not sensitive to impacts and blows than the heat treatment coating: because the thermal spray coating is only mechanically attached to the substrate, and the laser cladding layer is metallurgically combined with the gray cast iron substrate.

Summary: The cladding of the wear-resistant layer of the brake disc by laser can realize a reliable process with both technological and economical benefits in the future, thereby significantly reducing the emission of fine particles caused by braking. This can retain the cost-effective advantage of gray cast iron brake discs. The laser wear-resistant cladding process paves the way for the next generation of standardized brake discs. Senfeng has very mature technology and tons of practical experiences in laser cladding applications, please contact for more detailed info from our experts.

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