Brake disk and method for producing a brake disk

Patent metadata

Field	Value
Publication number	US-2020072306-A1
Application number	US-201916560065-A
Country	US
Kind code	A1
Filing date	Sep 4, 2019
Priority date	Sep 4, 2018
Publication date	Mar 5, 2020
Grant date	—

Abstract

A brake disk for a wheel brake of a land vehicle includes a main body formed from gray cast iron. The main body has at least one axial friction side, at least one anti-corrosion layer applied to the axial friction side, and at least one anti-abrasion layer applied to the anti-corrosion layer. The anti-corrosion layer is a cost-effective coating for the brake disk that enables enhanced corrosion resistance and is provided as a sherardizing layer. The anti-abrasion layer is wear resistant for the at least one frictional face of the brake disk and is provided by a SiC material containing at least one oxidic or metallic binder, or by an iron-based alloy having a vanadium carbide reinforcement, a niobium carbide reinforcement, a boron carbide reinforcement, a chromium carbide reinforcement or combinations thereof.

First claim

What is claimed is:

1 . A brake disk for a wheel brake of a land vehicle, the brake disk comprising:
a main body formed from gray cast iron and having at least one axial friction side; at least one anti-corrosion layer applied to the axial friction side, wherein the at least one anti-corrosion layer is a sherardizing layer; and at least one anti-abrasion layer applied to the anti-corrosion layer.

2 . The brake disk according to claim 1 , wherein the surface of the main body to which the at least on anti-corrosion layer is applied is roughened.

3 . The brake disk according to claim 1 , wherein the at least one anti-corrosion layer is a zinc-rich anti-corrosion layer.

4 . The brake disk according to claim 3 , wherein the at least one anti-corrosion layer has a hardness of about 40 HRC.

5 . The brake disk according to claim 1 , wherein the at least one anti-abrasion layer is produced from a SiC material containing at least one oxidic or metallic binder.

6 . The brake disk according to claim 5 , wherein the SiC material is SiC particles with a particle size of about 1 μm.

7 . The brake disk according to claim 1 , wherein the at least one anti-abrasion layer is produced from an iron-based alloy having a vanadium carbide reinforcement or a niobium carbide reinforcement or a boron carbide reinforcement or a chromium carbide reinforcement.

8 . The brake disk according to claim 1 , wherein the at least one anti-abrasion layer is produced from an iron-based alloy with a vanadium content of more than about 6% by weight.

9 . The brake disk according to claim 1 , wherein the at least one anti-abrasion layer is produced from an iron-based alloy with a niobium content of more than about 8% by weight.

10 . The brake disk according to claim 1 , wherein the at least one anti-abrasion layer is produced from an iron-based alloy with a chromium content of more than about 17% by weight and a boron content of at least 2% by weight.

11 . The brake disk according to claim 1 , wherein the at least one anti-abrasion layer is produced from an iron-based alloy with chromium carbides.

12 . A brake disk for a wheel brake of a land vehicle, the brake disk comprising:
a gray cast iron main body with at least one axial friction side; a sherardized zinc-rich anti-corrosion layer on the axial friction side; and an anti-abrasion layer on the anti-corrosion layer.

13 . The brake disk according to claim 12 , wherein the anti-abrasion layer is produced from a SiC material containing at least one oxidic or metallic binder.

14 . The brake disk according to claim 12 , wherein the anti-abrasion layer is produced from an iron-based alloy having a reinforcement selected from at least one of a vanadium carbide reinforcement, a niobium carbide reinforcement, a boron carbide reinforcement, and a chromium carbide reinforcement.

15 . A method for producing a brake disk for a wheel brake of a land vehicle, the method comprising:
applying an anti-corrosion layer to at least one axial friction side of a main body produced from gray cast iron, wherein the anti-corrosion layer is applied using a sherardizing method; and applying an anti-abrasion layer to the anti-corrosion layer.

16 . The method according to claim 15 further comprising performing, to the axial friction side of the main body, a machining operation involving turning prior to applying the anti-corrosion layer.

17 . The method according to claim 15 further comprising roughening the axial friction side using at least one of a high-pressure waterjet method and a machining method prior to applying the anti-corrosion layer.

18 . The method according to claim 15 , wherein the anti-abrasion layer is applied to the anti-corrosion layer using high-velocity flame spraying.

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

20 . The method according to claim 15 , wherein the anti-abrasion layer is applied to the anti-corrosion layer using high-velocity flame spraying with liquid fuel.

Assignees

• Ford Global Tech Llc

Inventors

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

Classifications

• F16D2250/0046

  Coating · CPC title

• F16D2065/132

  layered · CPC title

• F16D2200/0013

  Cast iron · CPC title

• F16D65/12 Primary

  Discs; Drums for disc brakes · CPC title

• C09D5/084

  Inorganic compounds · CPC title