Brake disk and method for producing a brake disk

Patent metadata

Field	Value
Publication number	US-11725704-B2
Application number	US-202217743127-A
Country	US
Kind code	B2
Filing date	May 12, 2022
Priority date	Sep 4, 2018
Publication date	Aug 15, 2023
Grant date	Aug 15, 2023

Abstract

A method for producing a brake disk for a wheel brake of a land vehicle includes laser depositing a duplex steel anti-corrosion layer to an axial friction side of a main body produced from gray cast iron at a surface speed of more than 10 m/min and applying an anti-abrasion layer to the anti-corrosion layer.

First claim

What is claimed is:

1. A method for producing a brake disk for a wheel brake of a land vehicle, the method comprising:
laser depositing a duplex steel anti-corrosion layer to an axial friction side of a main body produced from gray cast iron at a surface speed of more than 10 m/min, the laser depositing comprising continuously introducing a duplex steel powder into a laser beam and at the same time continuously introducing a carbide powder into the laser beam; and
applying an anti-abrasion layer to the anti-corrosion layer.

2. The method according to claim 1 further comprising machining the axial friction side of the main body prior to applying the anti-corrosion layer, wherein the machining includes turning the axial friction side.

3. The method according to claim 1 further comprising smoothing a surface of the anti-corrosion layer which faces away from the main body prior to applying the anti-abrasion layer.

4. The method according to claim 1 further comprising smoothing a surface of the anti-abrasion layer which faces away from the anti-corrosion layer.

5. The method according to claim 1 , wherein the anti-abrasion layer is applied to the anti-corrosion layer using laser deposition.

6. The method according to claim 1 , wherein the anti-abrasion layer is applied to the anti-corrosion layer using high-velocity flame spraying.

7. The method according to claim 1 , wherein the duplex steel powder is introduced via a first powder line and the carbide powder is introduced via a second powder line.

8. The method according to claim 1 , wherein the laser depositing the duplex steel anti-corrosion layer to the axial friction side of the main body comprises using a quasi-coaxial multi-jet powder nozzle, wherein the quasi-coaxial multi-jet powder nozzle comprises a design working clearance greater than 20 mm, glass powder injector inserts with a smooth and hard internal surface, and a shielding gas stream.

9. The method according to claim 1 , wherein the anti-abrasion layer is applied with high-velocity flame spraying using an HVOF burner with liquid fuel and four powder injectors.

10. The method according to claim 1 , wherein the anti-abrasion layer is produced from an iron-based alloy having a carbide reinforcement, the carbide reinforcement comprising at least one of a silicon carbide reinforcement, a vanadium carbide reinforcement, a niobium carbide reinforcement, a boron carbide reinforcement, and a chromium carbide reinforcement.

11. The method according to claim 1 , wherein the main body is produced using a sand casting method.

12. A method for producing a brake disk for a wheel brake of a land vehicle, the method comprising:
laser depositing a duplex steel anti-corrosion layer to an axial friction side of a main body produced from gray cast iron at a surface speed of more than 10 m/min, wherein the anti-corrosion layer is based on iron and has a chromium content of between 18% by weight and 30% by weight, a nickel content of between 1% by weight and 8% by weight, a molybdenum content of at most 4.5% by weight, a copper content of at most 3% by weight and a carbon content of at most 0.03% by weight; and
applying an anti-abrasion layer to the anti-corrosion layer.

13. The method according to claim 12 further comprising machining the axial friction side of the main body prior to applying the anti-corrosion layer, wherein the machining includes turning the axial friction side.

14. The method according to claim 12 further comprising smoothing a surface of the anti-corrosion layer which faces away from the main body prior to applying the anti-abrasion layer.

15. The method according to claim 12 further comprising smoothing a surface of the anti-abrasion layer which faces away from the anti-corrosion layer.

16. The method according to claim 12 , wherein the anti-abrasion layer is applied to the anti-corrosion layer using laser deposition.

17. A method for producing a brake disk for a wheel brake of a land vehicle, the method comprising:
laser depositing a duplex steel anti-corrosion layer to an axial friction side of a main body produced from gray cast iron at a surface speed of more than 10 m/min, wherein the anti-corrosion layer is based on iron and has a chromium content of between 18% by weight and 30% by weight, a nickel content of between 1% by weight and 8% by weight, a molybdenum content of at most 4.5% by weight, a copper content of at most 3% by weight and a carbon content of at most 0.03% by weight; and
applying an anti-abrasion layer to the anti-corrosion layer, wherein the anti-abrasion layer is produced from an iron-based alloy having a carbide reinforcement, the carbide reinforcement comprising at least one of a silicon carbide reinforcement, a vanadium carbide reinforcement, a niobium carbide reinforcement, a boron carbide reinforcement, and a chromium carbide reinforcement.

18. The method according to claim 17 , wherein the laser depositing the duplex steel anti-corrosion layer to the axial friction side of the main body comprises introducing continuously and at the same time a duplex steel powder and a carbide powder into a laser beam.

19. The method according to claim 17 , wherein the laser depositing the duplex steel anti-corrosion layer to the axial friction side of the main body comprises using a quasi-coaxial multi-jet powder nozzle, wherein the quasi-coaxial multi-jet powder nozzle comprises a design working clearance greater than 20 mm, glass powder injector inserts with a smooth and hard internal surface, and a shielding gas stream.

20. The method according to claim 17 , wherein the anti-abrasion layer is applied with high-velocity flame spraying using an HVOF burner with liquid fuel and four powder injectors.

Assignees

• Ford Global Tech Llc

Inventors

• Rettig Marc Oliver
• Grochowicz Jaroslaw
• Grabiec Tomasz Pawel
• Verpoort Clemens Maria
• Wank Andreas
• Hitzek Alexander
• Schmengler Christian
• Müller-Roden Karin
• Kaesgen Klaus

Classifications

• F16D65/125 Primary

  characterised by the material used for the disc body · CPC title

• B23K26/342

  Build-up welding · CPC title

• C22C38/42 Primary

  with copper · CPC title

• C22C38/44

  with molybdenum or tungsten · CPC title

• F16D69/02

  Composition of linings {; Methods of manufacturing} · CPC title