Brake disk and method for producing a brake disk

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.

Claims

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, 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 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 has a carbide reinforcement.

3. The brake disk according to claim 2, wherein the carbide reinforcement is at least one of a niobium carbide reinforcement and a vanadium carbide reinforcement.

4. 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.

5. The brake disk according to claim 4, wherein the SiC material is SiC particles with an approximate size of 1 μm surrounded with the at least one oxidic or metallic binder.

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

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 niobium content of more than about 8% 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 chromium content of more than about 17% by weight and a boron content of at least 2% 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 chromium carbides.

11. 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.

Description

DRAWINGS

(1) 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:

(2) FIG. 1 shows a schematic axial section through an illustrative form of a brake disk according to the present disclosure; and

(3) FIG. 2 shows a flow diagram of an illustrative form of a method according to the present disclosure.

(4) 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

(5) 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.

(6) 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).

(7) 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.

(8) 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).

(9) 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.

(10) 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.

(11) 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.

(12) 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.

(13) 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.

(14) 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.

(15) 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.”

(16) 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.