BRAKE DISK AND METHOD FOR PRODUCING A BRAKE DISK

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.

Claims

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; 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 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.

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.

Description

DRAWINGS

[0041] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

[0042] FIG. 1 shows a schematic axial section through an illustrative form of a brake disk according to the present disclosure; and

[0043] FIG. 2 shows a flow diagram of an illustrative form of a method according to the present disclosure.

[0044] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

[0045] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0046] FIG. 1 shows a schematic axial section through an illustrative form of a brake disk 1 according to the present disclosure for a wheel brake (not shown) of a land vehicle (not shown).

[0047] The brake disk 1, which is of annular design, has a main body 2 of annular design, formed from gray cast iron, having an axial friction side 3, an anti-corrosion layer 4 of annular design applied to the axial friction side 3, and a duplex steel anti-abrasion layer 5 of annular design applied to the anti-corrosion layer 4.

[0048] The anti-corrosion layer 4 based on iron 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. Moreover, the anti-corrosion layer 4 has a carbide reinforcement (not shown).

[0049] The anti-abrasion layer 5 can be produced from a SiC material containing at least one oxidic or metallic binder. Alternatively, the anti-abrasion layer can be 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.

[0050] FIG. 2 shows a flow diagram of one illustrative form of a method according to the present disclosure for producing a brake disk for a wheel brake of a land vehicle. The finished brake disk can be configured as shown in FIG. 1.

[0051] In step 10, a main body composed of gray cast iron is produced, having at least one axial friction side. For this purpose, a sand casting method can be employed.

[0052] In step 20, an anti-corrosion layer is applied to the axial friction side of the main body. The anti-corrosion layer is produced using a laser deposition method, in which a duplex steel is applied to the axial friction side at a surface speed of more than 10 meters per minute (m/min). The axial friction side can be subjected to a machining operation involving turning before the application of the anti-corrosion layer. In the laser deposition method, a duplex steel powder and, at the same time, a carbide powder can be introduced continuously into a laser beam.

[0053] In step 30, an anti-abrasion layer is applied to the anti-corrosion layer. In this process, the anti-abrasion layer can be applied to the anti-corrosion layer using a laser deposition method or a high-velocity flame spraying method. A surface of the anti-corrosion layer which faces away from the main body can be smoothed before the application of the anti-abrasion layer. Finally, a surface of the anti-abrasion layer which faces away from the anti-corrosion layer can be smoothed.

[0054] Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice; material, manufacturing, and assembly tolerances; and testing capability.

[0055] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

[0056] The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.