Coatings for Automotive Gray Cast Iron Brake Discs: A Review
Abstract
:1. Introduction
2. Coating Technologies for Brake Discs
2.1. Non-Thermal Spray Processes
2.1.1. Hard Chrome Plating
2.1.2. Plasma Electrolytic Oxidation (PEO)
2.1.3. Laser Cladding
2.1.4. Plasma Transferred Arc (PTA)
2.2. Thermal Spray Processes
2.2.1. Atmospheric Plasma Spray (APS)
2.2.2. High Velocity Oxy-Fuel (HVOF)
2.2.3. Cold Gas Dynamic Spray (CGDS)
2.2.4. High Velocity Air Fuel (HVAF)
2.2.5. Suspension Plasma Spray (SPS)
3. Coating Materials
3.1. Oxides
3.2. Carbides
3.3. Alternative Materials
4. Industrial Implications
5. Conclusions
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Material | Melting Point (°C) | Bulk Density (g/cm3) | Thermal Conductivity (W/m.K(°C)) | Thermal Expansion Coefficient (µstrain/°C) | Vickers Hardness (HV) | Youngs Modulus (GPa) | Poisson’s Ratio |
---|---|---|---|---|---|---|---|
GCI | 1200 | 7.2 | 50–72 | 11–13 | 90–216 | 80–100 | 0.27 |
Al-12SiC | 630 | 2.8 | 120–130 | 17.7–18 | 91–138 | 94–98 | 0.3 |
Ti 6Al-4V | 1600 | 4.43 | 8–9 | 8.7–9.1 | 332–336 | 113–115 | 0.34 |
Carbon-carbon composite | 3300 | 1.7 | 13–35 | 1.1–8.4 | 42–46 | 71–79 | 0.32 |
Coating Process | Source | Possible Coatings | Microstructural Features | References | Drawbacks |
---|---|---|---|---|---|
Hard chrome plating | Electrolyte | CrO3 | Metallurgical bonding, highly dense and thin coating | [35,36] | Hexavalent Chromium—carcinogenic |
PEO | Electrolyte | Oxides of Al, Mg, Ti | Protective oxide scale, metallurgical bonding and uniform coating thickness | [48,49,71] | Suited only for few metals like Al, Mg, Ti, and their alloys capable of forming protective oxides by chemical conversion |
Laser Cladding | Wire or powder | Wide range of Metals alloys, cermets and ceramics | Metallurgical bonding, dense and thick coatings | [57,62,65,72,73] | Different laser beam absorptivity at GCI surface can result in non-homogeneous thermal fields; excessive heating can lead to thermal damage to feedstock (e.g., decarburization of WC to W2C) |
PTA | Wire or powder | Wide range of Metals, alloys, cermets and ceramics | Metallurgical bonding, dense and thick coatings | [66,70,74,75] | Possibility of dilution from cast iron, to change coating composition and influence mechanical properties |
Coating Process | Coating Material | Substrate | Coating Hardness | CoF | Counter Body | Ref. |
---|---|---|---|---|---|---|
APS | TinO2n−1 (n = 4–6) | GCI | 846 HV0.2 | 0.58–0.78 | Sintered Al2O3 ball | [90] |
APS | 8YSZ | 4130 steel brake discs | – | 0.55 | Fe-Cu pad | [91] |
ZrO2 | 1400 HV0.2 | 0.65 | ||||
75Cr3C2-25NiCr | 800 HV0.2 | 0.35 | ||||
APS | Al2O3-TiO2 | GCI brake disc | – | 0.27 | As per SAE J2522 dynamometer test | [92] |
APS | Cr2O3-40% TiO2 | GCI brake disc | 842 HV0.5 | 0.49 | As per SAE J2522 dynamometer test | [94] |
APS | Cr2O3 | Cast iron | 1200 HV0.1 | 0.60 | Self-mated Cr2O3-coated discs | [180] |
APS | Cr2O3-5MoO3 | Cast iron | 1700 HV0.1 | 0.40 | Cr-plated disc | [175] |
APS | Al2O3 | Cast iron | 1150 HV0.3 | 0.45–0.55 | D2 steel disc | [185] |
APS | 8YSZ | Cast iron | 980 HV0.1 | 0.85 | Cr-plated disc | [186] |
20YSZ | 450 HV0.1 | 0.90 | ||||
ZrO2 + 5CaO | 300 HV0.1 | 0.80–0.55 | ||||
Al2O3-ZrO2 | 960 HV0.1 | 0.80–0.70 | ||||
APS | Mo | Cast iron | 500 HV0.1 | – | AISI 303 steel pin | [187] |
Coating Process | Coating Material | Substrate | Coating Hardness | CoF | Counter Body | Ref. |
---|---|---|---|---|---|---|
HVOF | Co-30Cr-12W-2.4C | Gray cast iron | 812 HV0.3 | 0.30–0.35 | Non-asbestos organic (NAO) brake pad material | [6] |
HVOF | 75Cr3C2-25NiCr | Gray cast iron | 766 HV0.2 | 0.29–0.36 | As per SAE J2522 dynamometer test | [92] |
HVOF | 75Cr3C2-25NiCr | Gray cast iron | 766 HV0.2 | – | 10 mm diameter Al2O3 ball | [93] |
HVOF | 80Cr3C2-20NiCr | Gray cast iron | 1410 HV0.3 | 0.20–0.24 | WC-6Co pin | [117] |
HVOF | 86WC-10Co-4Cr | Cast iron | 1100 HV0.3 | 0.48–0.49 | Commercial low-metallic friction material | [119] |
HVOF | 75Cr3C2-25NiCr | Pearlitic cast iron | 920 HV0.3 | 0.43–0.59 | Commercial low-metallic friction material | [118] |
HVOF | 86WC-10Co-4Cr | Pearlitic cast iron | 1130 HV0.3 | 0.30–0.66 | Commercial low-metallic friction material | [118] |
HVOF | 88WC-12Co | Gray cast iron | 510 HV0.2 | 0.51–0.52 | Low-metallic friction material | [120] |
HVOF | 86WC-10Co-4Cr | Cast iron | – | 0.48–0.49 | Experimental | [121] |
Material | Bulk Density (g/cm3) | Thermal Conductivity (W/m.K (°C)) | Thermal Expansion Coefficient (K−1 × 10−6) | Vickers Hardness (HV) | Ref. |
---|---|---|---|---|---|
Al2O3 | 3.65–3.96 | 30–36 | 4.50–8.30 | 1520–1680 | [20] |
Cr2O3 | 4.20–4.40 | 10–33 | 7.80–8.10 | 1280–1420 | [20] |
Fe-V-Cr-C alloy | 7.50 | – | – | 800–950 | [113] |
WC-FeCrAl | 14.42 | – | 6.17–6.68 | 950–1200 | [204,205] |
75Cr3C2-25NiCr | 7 | 14 | 11.10 | 1350 | [206] |
WC-17Co | 14.54 | 81.50 | – | 1060–1170 | [207] |
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Aranke, O.; Algenaid, W.; Awe, S.; Joshi, S. Coatings for Automotive Gray Cast Iron Brake Discs: A Review. Coatings 2019, 9, 552. https://doi.org/10.3390/coatings9090552
Aranke O, Algenaid W, Awe S, Joshi S. Coatings for Automotive Gray Cast Iron Brake Discs: A Review. Coatings. 2019; 9(9):552. https://doi.org/10.3390/coatings9090552
Chicago/Turabian StyleAranke, Omkar, Wael Algenaid, Samuel Awe, and Shrikant Joshi. 2019. "Coatings for Automotive Gray Cast Iron Brake Discs: A Review" Coatings 9, no. 9: 552. https://doi.org/10.3390/coatings9090552