Simulation of thermal and mechanical performance of laser cladded disc brake rotors

• Disc brakes wear during braking events and release airborne particulates. These particle emissions are currently one of the highest contributors to non-exhaust particle emissions and introduce health hazards as well as environmental contamination. To reduce this problem, wear and corrosion-resistant disc coatings have been implemented on grey cast iron brake disc rotors by using various deposition techniques such as thermal spraying and overlay welding. High thermal gradients during braking introduce risks of flaking off and cracking of thermally sprayed coatings with adhesive bonding to the substrate. Overlay welding by laser cladding offers metallurgical bonding of the coating to the substrate and other benefits that motivate laser cladding as a candidate for the coating of the grey cast iron brake discs. This study aims to investigate the effect of laser cladding on the thermal and thermo-structural performance of the coated grey cast iron brake discs. Therefore, thermal and thermo-stress analysis with COMSOL Multiphysics 5.6 software is performed on braking events of grey cast iron brake discs as non-coated – reference and laser cladding coated with stainless steel welding consumables. The Results demonstrated that surface temperatures were more localised, overall higher in the laser cladded coating with over three times the stresses attained of reference grey cast iron discs. The output of the simulations has been compared by tests found in the literature. Laser cladding presented higher reliability and braking performance, nonetheless requiring the evaluation of its thermal impact on other system components. 

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Maskinteknik -- Tribologi (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Mechanical Engineering -- Tribology (hsv//eng)

Nyckelord

coating

disc brakes

friction

grey cast iron

laser cladding

thermal performance

thermal stress

Adhesives

Brakes

Cast iron

Cladding (coating)

Corrosion resistance

Corrosion resistant coatings

Disks (machine components)

Disks (structural components)

Health hazards

Iron metallurgy

Sprayed coatings

Stress analysis

Structural analysis

Thermal spraying

Wear of materials

Welding

Airborne particulate

Deposition technique

Environmental contamination

Mechanical performance

Metallurgical bonding

Structural performance

Surface temperatures

Thermally sprayed coatings

Braking performance

coating

disc brakes

friction

grey cast iron

laser cladding

thermal performance

thermal stress

Publikations- och innehållstyp

ref (ämneskategori)

art (ämneskategori)