Brake disk and method for producing a brake disk

Patent metadata

Field	Value
Publication number	US-2020072307-A1
Application number	US-201916560108-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 duplex steel layer that provides a cost-effective coating for the brake disk and enables improved corrosion resistance. The anti-abrasion layer is wear resistant 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 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; and at least one anti-abrasion layer applied to the anti-corrosion layer, wherein the anti-corrosion layer is produced from a duplex steel.

2 . The brake disk according to claim 1 , wherein the at least one 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.

3 . The brake disk according to claim 1 , wherein the at least one anti-corrosion layer has a carbide reinforcement.

4 . The brake disk according to claim 3 , wherein the carbide reinforcement is at least one of a niobium carbide reinforcement and a vanadium carbide reinforcement.

5 . The brake disk according to claim 1 , wherein the at least one anti-abrasion layer has a carbide reinforcement.

6 . 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.

7 . The brake disk according to claim 6 , wherein the SiC material is SiC particles with an approximate size of 1 μm surrounded with the at least one oxidic or metallic binder.

8 . 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.

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 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 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 at least one anti-abrasion layer comprising a carbide reinforcement applied to the anti-corrosion layer.

13 . 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; and applying an anti-abrasion layer to the anti-corrosion layer.

14 . The method according to claim 13 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.

15 . The method according to claim 13 further comprising smoothing a surface of the anti-corrosion layer which faces away from the main body prior to applying the anti-abrasion layer.

16 . The method according to claim 13 further comprising smoothing a surface of the anti-abrasion layer which faces away from the anti-corrosion layer.

17 . The method according to claim 13 , wherein the anti-abrasion layer is applied to the anti-corrosion layer using laser deposition or high-velocity flame spraying.

18 . The method according to claim 13 , 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 13 , 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 13 , 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

Classifications

• F16D69/027

  Compositions based on metals or inorganic oxides · CPC title

• B23K2103/05

  Stainless steel · CPC title

• F16D2065/132

  layered · CPC title

• B23K26/34

  Laser welding for purposes other than joining · CPC title

• F16D2250/00

  Manufacturing; Assembly · CPC title