Process for producing a protective coating on a brake side of a brake disk main element and process for producing a brake disk

Patent metadata

Field	Value
Publication number	US-11635117-B2
Application number	US-202117204391-A
Country	US
Kind code	B2
Filing date	Mar 17, 2021
Priority date	Mar 17, 2020
Publication date	Apr 25, 2023
Grant date	Apr 25, 2023

Abstract

A process for producing a protective coating on a brake side of a brake disk main element includes using a laser powder build-up welding process. An NbC metal matrix powder or a Cr3C2 metal matrix powder is produced by agglomeration and sintering of NbC particles or Cr3C2 particles with particles of a metallic matrix composed of a stainless steel. During the laser powder build-up welding process, the NbC metal matrix powder or the Cr3C2 metal matrix powder and an aluminum alloy powder is supplied simultaneously to a molten surface region of the brake disk main element which has been melted by a laser.

First claim

What is claimed is:

1. A process for producing a protective coating at least on a brake side of a brake disk main element, the process comprising:
producing at least one of an NbC metal matrix powder and a Cr 3 C 2 metal matrix powder by agglomeration and sintering at least one of NbC particles and Cr 3 C 2 particles, respectively, with particles of a metallic matrix composed of a stainless steel; and
producing a protective coating using a laser powder build-up welding process, wherein during the laser powder build-up welding process the at least one of the NbC metal matrix powder and the Cr 3 C 2 metal matrix powder is supplied simultaneously with an aluminum alloy powder to a molten surface region of the brake disk main element melted by a laser.

2. The process according to claim 1 , wherein the NbC metal matrix powder is NbC—FeCr powder and the Cr 3 C 2 metal matrix powder is Cr 2 C 2 —FeCr powder.

3. The process according to claim 1 , wherein the aluminum alloy powder is an aluminum-silicon alloy powder.

4. The process according to claim 1 , wherein a proportion of silicon in the aluminum alloy powder is between 12% by weight and 50% by weight.

5. The process according to claim 1 , wherein the NbC metal matrix powder and the Cr 3 C 2 metal matrix powder have a particle size in a range from 10 μm to 125 μm.

6. The process according to claim 1 , wherein the NbC metal matrix powder and the Cr 3 C 2 metal matrix powder have a particle size in a range from 15 μm to 45 μm.

7. The process according to claim 1 , wherein a proportion of NbC in the NbC metal matrix powder and a proportion of Cr 3 C 2 in the Cr 3 C 2 metal matrix powder is in the range from 50% by weight to 90% by weight.

8. The process according to claim 1 , wherein a proportion of NbC in the NbC metal matrix powder is in a range of 75% by weight to 85% by weight and a proportion of Cr 3 C 2 in the Cr 3 C 2 metal matrix powder is in a range from 70% by weight to 80% by weight.

9. The process according to claim 1 , wherein the laser powder build-up welding process is carried out using a multijet nozzle with at least four jets.

10. The process according to claim 1 , wherein the laser powder build-up welding process is carried out using a multijet nozzle with six jets.

11. The process according to claim 1 , wherein at least one of copper, iron, chromium and nickel are supplied simultaneously to the molten surface region of the brake disk main element during the laser powder build-up welding process.

12. The process according to claim 1 , wherein the brake side of the brake disk main element is composed of a gray cast iron and an aluminum alloy spray layer is applied to the brake side of the brake disk main element before carrying out the laser powder build-up welding process.

13. The process according to claim 12 , wherein the aluminum alloy spray layer is sintered together with the brake disk main element during the laser powder build-up welding process and the aluminum alloy spray layer is an Al—Mg spray layer.

14. A process for producing a brake disk with a brake disk main element composed of aluminum or an aluminum alloy, wherein a protective coating is produced at least on the brake side of the brake disk main element using the process according to claim 1 .

15. A process for producing a brake disk with a brake disk main element made of gray cast iron material, wherein an aluminum alloy spray layer is applied to the brake side of the brake disk main element made of gray cast iron, the spray layer is sintered together with the brake disk main element and a protective coating is produced at least on the brake side using the process according to claim 1 .

16. The process according to claim 15 , wherein the aluminum alloy spray layer is an Al—Mg spray layer.

17. The process according to claim 15 , wherein the brake side of the brake disk main element is roughened before application of the spray layer.

18. The process according to claim 15 , wherein the brake side of the brake disk main element is subjected to a turning process before roughening.

19. A process for producing a protective coating at least on a brake side of a brake disk main element, the process comprising:
producing at least one of an NbC—FeCr powder and a Cr 3 C 2 —FeCr powder by agglomeration and sintering of at least one of NbC particles and Cr 3 C 2 particles, respectively, with particles of a metallic matrix composed of a stainless steel; and
producing a protective coating using a laser powder build-up welding process, wherein during the laser powder build-up welding process the at least one of the NbC—FeCr powder and the Cr 3 C 2 —FeCr powder is supplied simultaneously with an aluminum alloy powder to a molten surface region of the brake disk main element melted by a laser.

20. The process according to claim 19 , wherein at least one of copper, iron, chromium and nickel is supplied simultaneously to the molten surface region of the brake disk main element during the laser powder build-up welding process.

Assignees

• Ford Global Tech Llc

Inventors

• Rettig Marc Oliver
• Kaesgen Klaus
• Verpoort Clemens Maria
• Grochowicz Jaroslaw
• Wank Andreas
• Schmengler Christian
• Krause Annika

Classifications

• F16D2200/006

  containing fibres or particles · CPC title

• F16D2250/0046

  Coating · CPC title

• C23C4/131

  Wire arc spraying · CPC title

• F16D69/027 Primary

  Compositions based on metals or inorganic oxides · CPC title

• F16D2200/003

  Light metals, e.g. aluminium · CPC title