The advent of electric vehicles has revolutionalized the automotive industry. In electric vehicles, brakes are less frequently used due to regeneration capacity. The challenge is that, in this scenario, rust is developed on the friction surfaces of gray cast iron (GCI) disc rotor which can affect the performance of the brake system and also generate nonexhaust particulate matter emissions. If GCI brake discs are to remain relevant in this new era, the problem of corrosion and wear must be addressed holistically using techniques that are not complex to implement industrially, easily adaptable, environmental sustainable and cost-efficient. A solution that could solve the corrosion issue of the whole disc is preffered.
Thanks in advance for your suggestions and contributions to this discussion.
@Pierluigi, thanks you very much for your comments. Yes, I agreed with you but there’s still need to improve GCI disc .
Sir Pierluigi Traverso I agree with you, but aluminum is a very big problem especially when the material is not made under vacuum, the aluminum will combine with nitrogen and it will form the AlN compound which is harmful for the manufacture of engine parts.
Dear Samuel A Awe,
in my opinion, an effective alternative is to coat the GCI with tungsten carbide (iDisc). This solution was developed by Buderus/Bosch and is already in series production in some Porsche models (Porsche Surface Coated Brake/PSCB). This disc coating offers the advantage of reduced susceptibility to rust and a significant reduction in wear (fine dust particles). I think that costs can be reduced as a result of mass production (volume segments)!
Dear Samuel A Awe,
Hard chrome plating, electroless nickel, and ferritic nitrocarburizing are some of the coating/diffusion I would recommend for a part like a rotor that needs a combination of wear and corrosion resistance. Do not hesitate to get in touch with me if you would like to collaborate on developing a suitable coating.
Best regards,
SCA
Thank you all for your response.
David Hesse how effective is the process you have mentioned in protecting the whole disc against corrosion, including the vents of the disc?
Atul Sc, have you tested these processes on grey iron material? Any information you can share!
Thank you both once again!
Samuel
Samuel A Awe It is not necessary to provide the entire disc with a hard metal coating! It is sufficient if the friction ring is coated with tungsten carbide and the remaining surfaces are provided with a much cheaper and well-known anti-corrosion coating (e.g. GEOMET or DACROMET).
Kind regards,
David
Samuel A Awe I agree with David Hesse's plan to selectively coat with WC. But I believe WC would be too expensive for a cutthroat industry like automobiles industry. Based on my experience in studying the wear loss by dry sand abrasion tests, nitriding reduced wear by only 22 %. But I believe hard chrome and EN would reduce by a minimum of 60%. Now again thinking about this, Hard chrome may not be a good choice I would recommend liquid nitriding followed by electroless nickel.
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