High-Performance Cold Spray Coating for Particle Emission Reduction and Wear & Corrosion Protection on Brake Discs
Recent environmental concerns have generated extensive friction brake system research and development intending to reduce particle emissions. Brake wear emissions are a growing apprehension for the automotive industry that requires a process that enables improved protective coating with an environmentally friendly material on gray cast iron brake disc with low production cost.
In the present work, different approaches concerning coating material are discussed with respect to performance, economic, and ecological aspects. High-performance composite coatings are developed on gray cast-iron brake discs using Impact Cold Spray System EvoCSII. The performance of the coating was evaluated in terms of corrosion resistance, wear resistance, and tensile bond strength between the coating and the brake disc. The cold gas sprayed composite coating showed a drastic reduction in particle emission by over 85% and >95% reduction in wear in the SAE J2522 test. In addition, the coating showed excellent adhesion even after extreme crack formation test runs without any delamination. Supplementary, 720 hours of salt spray tests were completed without corrosion. Present results demonstrate a cost-effective solution for brake disc application with cold sprayed composite coatings.