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7268 |
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Wednesday, May 04, 2022, Hall D 2:40 PM Automotive Industry |
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High-performance cold sprayed coating for brake disc wear |
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Jan Kondas / Impact Innovations GmbH, Germany Reeti Singh* / Impact Innovations GmbH, Germany Max Meinicke/ Impact Innovations GmbH, Germany Leonhard Holzgaßner/ Impact Innovations GmbH, Germany |
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Brake discs are a critical component of an automotive braking system transforming kinetic energy into thermal energy during braking, which raises the temperature of the disc friction surfaces. Brake wear emissions, such as brake dust and particulate matter, are a growing source of concern for the automotive industry. They contribute considerably to rising pollution levels and represent a problem in the face of more demanding stringent and environmental regulations. Gray cast iron is the commonly used material for brake discs because of its durability. However, poor corrosion resistance and excessive brake disc material wear during service remain topics of concern. Because gray cast iron is still the most used brake disc material for vehicles, coating gray cast-iron discs could be a viable solution to the problem. Present work developed a high-performance composite coating on gray cast-iron brake discs using the cold spray process. The performance of the coating was evaluated about corrosion resistance, wear resistance, hardness, and bonding strength between the coating and the brake disc. The cold sprayed composite coating on the gray cast-iron brake disc illustrates a 90 % reduction in wear during the SAE-J2522 test; moreover, no delamination of coatings was manifested. Furthermore, coatings survived 720 h of salt spray test for corrosion resistance. Present results demonstrate a cost-effective solution for brake disc application with cold sprayed composite coatings. |