#ehla

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New coating process provides effective protection for brake discs

More than many other auto parts, brake discs are subject to repeated mechanical loads. As a result of this continual abrasion, they produce fine particulate matter, which pose a substantial environmental burden. Now, however, a new coating process developed by the Fraunhofer Institute for Laser Technology ILT and RWTH Aachen University can significantly reduce this impact. By using "Extreme High-speed Laser Material Deposition", known by its German acronym EHLA, it has proved possible to provide brake discs with an effective protection against wear and corrosion in a procedure that is both fast and economic.

Traditional brake discs are made of gray cast iron containing lamellar graphite phases. The virtue of this material lies in its good thermal conductivity and high thermal capacity, all for a relatively low price. The downside is a strong propensity to corrode coupled with high material wear during service, which generates substantial emissions of fine particulate matter. To date, it has proved difficult to provide adequate protection for brake discs by means of conventional coating processes such as electroplating or thermal spraying. The problem with such processes is that they do not produce a metallurgical bond between the cast iron and the protective coating; moreover, they are expensive and use a lot of materials.

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