Metall

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Making Brakes fit for Euro 7 - Brake Disc coating with Cold Spray Technology

Emissionen von Bremsabnutzung, wie Bremsstaub und Feinstaub, geben der Automobilindustrie zunehmend Anlass zur Sorge und stellen angesichts immer strengerer und umweltpolitischer Vorschriften ein Problem dar. Grauguss mit eingebettetem Graphit ist der gängigste Werkstoff, aus dem Bremsscheiben hergestellt werden. Grauguss-Bremsscheiben sind nicht nur günstig in der Herstellung, sie verfügen auch über alle notwendigen mechanischen Eigenschaften, die benötigt werden. Da für KFZ-Bremsscheiben aus Kostensicht noch kein Werkstoff mit Grauguss konkurrieren kann, stellt die Beschichtung von Grauguss-Bremsscheiben eine praktikable und kostengünstige Lösung dar. Herkömmliche thermische Beschichtungsverfahren sind jedoch noch sehr material- und kostenintensiv und die geforderten Eigenschaften hinsichtlich Schichthaftung, Korrosionsbeständigkeit und Rissverhalten können noch nicht erfüllt werden. Im Gegensatz zum Laserauftragschweißen gibt es für das Coldspray-Verfahren keinen Patentschutz eines großen Automobilherstellers. Mehr Infos unter: https://impact-innovations.com/anwendungsbeispiele/kaltgasgespritzte-bremsscheib/ --- Brake wear emissions, encompassing brake dust and particulate matter, have emerged as a mounting concern for the automotive industry in light of stricter environmental regulations set by the EU. Brake discs predominantly originate from gray cast iron infused with embedded graphite. These gray cast iron brake discs not only offer cost-effective manufacturing but also encompass the essential mechanical attributes required. While no other material currently matches the cost efficiency of gray cast iron for vehicle brake discs, coating such discs provides a practical and budget-friendly solution. However, traditional thermal coating methods remain costly in terms of both materials and expenses, and they are unable to consistently meet the required criteria for coating adhesion, corrosion resistance, and resistance to cracking. In contrast, the cold spray process, unlike laser cladding, is unencumbered by patent restrictions from any major automotive manufacturer. More Infos at: https://impact-innovations.com/en/applications/cold-sprayed-brake-disc/ © by Impact Innovations GmbH Visit impact-innovations.com for more information. Contact us today: Impact Innovations GmbH Bürgermeister-Steinberger-Ring 1 84431 Rattenkirchen GERMANY +49 8636 695190-0 info@impact-innovations.com

impact

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Impact Innovations - Cold Spray Process

In comparison to conventional thermal spray processes, cold gas spraying offers special advantages, because the spraying material is neither fused nor melted during the process. Thus, the thermal influence on the coating and the substrate material is minimized. The high kinetic energy of the particles and the high degree of deformation during the impact on the substrate that is connected with it, allows the manufacturing of homogenous and very dense coatings. The range of coating thicknesses varies from just a few hundredths of a millimeter up to several centimeters. There are mainly metallic coatings produced, which physical and chemical properties barely differ from the properties of the base material. With the latest system technology of Impact Innovations GmbH a process gas - preferably nitrogen or helium - is put into a spray gun with a pressure of up to 50 bar (725 psi) and is heated up to a maximum temperature of 1100 °C (2012 °F) in the gun housing. The subsequent expansion of the heated and high pressurized gas in a convergent-divergent nozzle down to ambient pressure results in the acceleration of the process gas up to supersonic speed and, at the same time, in the cooling down of the gas to a temperature below 100 °C (373 °F). The spray powders are injected in the convergent section of the nozzle by using a powder feeding unit and carrier gas and are accelerated to a particle speed of up to 1200 m/s in the main gas stream. In the highly focused spray jet particles impinge the - in most cases untreated - surface of the component, deform the particles and form a strongly adhesive/cohesive and low-oxide coating.

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