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 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.

Claims

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 m.

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.

Description

DRAWINGS

[0047] 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:

[0048] FIG. 1 shows a schematic axial section through an illustrative form of a brake disk according to the present disclosure; and

[0049] FIG. 2 shows a flow diagram of an illustrative form of a method according to the present disclosure.

[0050] 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

[0051] 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.

[0052] 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).

[0053] 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 an anti-abrasion layer 5 of annular design applied to the anti-corrosion layer 4. The anti-corrosion layer 4 is a sherardizing layer. The surface of the axial friction side 3 of the main body 2, connected to the anti-corrosion layer 4, is roughened.

[0054] 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 5 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.

[0055] 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.

[0056] 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. The axial friction side is first subjected to machining involving turning. After that, the axial friction side is roughened using a high-pressure waterjet method.

[0057] In step 20, an anti-corrosion layer is applied using a sherardizing method to the axial friction side of the main body.

[0058] In step 30, an anti-abrasion layer is applied to the anti-corrosion layer using a high-velocity flame spraying method. Finally, a surface of the anti-abrasion layer which faces away from the anti-corrosion layer can be smoothed.

[0059] 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.

[0060] 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.

[0061] 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.