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The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc

Year 2020, Volume: 23 Issue: 3, 755 - 761, 01.09.2020
https://doi.org/10.2339/politeknik.563277

Abstract

The movement of moving devices or machines in terms of safety
perspective must be controlled. In modern vehicle applications, braking is
closely related to safety. Slowing or breaking the movements of vehicles safely
is the task of braking mechanisms. The most important components of these mechanisms
are the disc and brake lining pairs. Brake discs are made of lamella graphite
cast iron. During the braking, the kinetic energy of the vehicle is converted
into the heat energy through friction. The braking elements are subject to very
heavy thermo mechanical conditions under heat, speed and load. The friction and
wear properties of the brake disc must be thermally more stable against the
heat energy generated on it in order to maintain stability. In this study,
mechanical properties of the brake discs, which the disc surface was coated
with flame spraying and melting, were improved. In addition, microstructure,
abrasion, hardness and surface roughness tests of the brake disc were
conducted. As a result, the coated disc showed superior mechanical properties
compared to the original disc.

References

  • Mutlu I., Eldogan O. and Fındk F., "Tribological properties of some phenolic composites suggested for automotive brakes", Tribology International, 39:317-325, (2006)
  • Wu Y., Ma Y., Gao W., Yang G., Fu H., Xi N. and Chen H., "High temperature wear performance of laser cladding CoO6 coating on high-speed train brake disc", Applied Surface Science, 481:761-766, (2019)
  • Rachidi R., Kihel B. E. and Delaunois F., "Microstructure and mechanical characterization of NiCrBSi alloy and NiCrBSi-WC composite coatings produced by flame spraying", Materials Science-Engineering, 241:13-21 (2019)
  • Demir A., Samur R. and Kılıçaslan I., "Investigation of the coatings applied onto brake discs on disc-brake pad pair", Metalurgija, 48(3): 161-166, (2009)
  • Wang J., Fu Z.K., Guo J., Zhang Y.Q., Liu Q.Y. and Zhu M.H., "Investigation on wear resistance and fatigue damage of laser cladding coating on wheel and rail materials under the oil lubrication condition". Tribology Transactions, 59(5):810-817, (2016)
  • Wu Y., Liu Y., Chen H., Chen Y., Li H. and Yi W., "Microstructure evolution and crack propagation feature in thermal fatigue of laser deposited Stellite 6 coating for brake discs", Surface-Coatings Technology, 358: 98-107, (2019)7. Zamani P. and Valefi Z., "Microstructure, phase composition and mechanical properties of plasma sprayed Al2O3, Cr2O3 and Cr2O3-Al2O3 composite coatings", Surface-Coatings Technology, 316:138-145, (2017)
  • Poirier D., Legoux J.G., Irissou E., Gallant D., Jian, J., Potter T. and Boileau J., "Performance assessment of protective thermal spray coatings for lightweight al brake rotor disks", Journal of Thermal Spray Technology, 28 (1-2): 291-304, (2019)
  • Güney B. and Mutlu İ., "Tribological properties of brake discs coated Cr2O3-40%TiO2 by plasma spraying", Surface Review And Lettres, (2019)
  • Tucker R.C., "Thermal spray coatings", ASM Handbook, 5:497-509, (1994)
  • Evkaya M., "Metallere aşınmaya karşı yapılan kaplamada uygun toz materyali ve kaplama yönteminin bilgisayar destekli seçimi", Yüksek Lisans Tezi, Marmara Üniversitesi Fen Bilimleri Enstitüsü, İstanbul, (2003)
  • Gonzalez R., Cadenas M., Fernandez R., Cortizo J.L. and Rodriguez E., "Wear behaviour of flame sprayed NiCrBSi coating remelted by flame or by laser", Wear, 262: 301-307, (2007)
  • http://www.ep-coatings.co.uk/processes/flame-spraying/, Received on May 11, 2019
  • Schwartz M., "Encyclopedia of materials", Parts and Finishes 2 nd ed., CRC Pressb LLC, 895, (2002)
  • Salman S., "Plazma ve alev püskürtme tekniğiyle Al2O3-%13TiO2 ve Cr2O3-%5SiO2-%3TiO2 seramik kaplanan malzemelerin özellikleri", Doktora Tezi, Yıldız Teknik Üniversitesi, Fen Bilimleri Enstitüsü, İstanbul, (1995)
  • https://www.oerlikon.com/ecomaXL/files/oerlikon_BRO-0001.17_TS_MaterialGuide_EN.pdf , Received on May 11, 2019
  • Rodrıguez J., Martin A., Fernandez R. and Fernandez J. E., "An experimental study of the wear performance of NiCrBSi thermal spray coatings", Wear, 255: 950-955, (2003)
  • Miguel J.M., Guilemany J.M. and Vizcaino S. "Tribological study of NiCrBSi coating obtained by different processes", Tribology International, 36(3): 181-187, (2003)
  • Hidalgo V.H., Varela F.J.B., Menendez A.C. and Martinez, S.P., "A comparative study of high-temperature erosion wear of plasma sprayed NiCrBSiFe and WC-NiCrBSiFe coatings under simulated coal-fired boiler conditions", Tribology International, 34:161-169, (2001)
  • Ming Q., Lim L.C. and Chen, Z.D. "Laser cladding of nickel - based hardfacing alloys", Surface-Coatings Technology, 106: 174-182, (1998)
  • Wu P., Zhou C. Z. and Tang X. N., "Microstructural characterization and wear behavior of laser cladded nickel-based and tungsten carbide composite coatings", Surface-Coatings Technology, 166:84-88, (2003)
  • Serres N., Hlawka F., Costil S., Langlade C. and Machi F., "Microstructures of metallic NiCrBSi coatings manufactured via hybrid plasma spray and in situ Laser remelting process", Journal of Thermal Spray Technology, 20(1-2):336-343, (2011)
  • Grivc U., Derzic D. and Simon Muhic S., "Numerical optimisation and experimental validation of divided rail freight brake disc crown", Journal of Modern Transportation, 27(1):1-10, (2019)
  • Hong S., Wu Y., Li G., Wang B., Gao W. and Ying, G., "Microstructural characteristics of high-velocity oxygen-fuel (HVOF) sprayed nickel-based alloy coating", Journal of Alloys and Compounds, 581:398-403, (2013)
  • Bergant Z., Trdan U. and Grum J., "Effect of high-temperature furnace treatment on the microstructure and corrosion behavior of NiCrBSi flame-sprayed coatings", Corrosion Science, 88:372-386, (2014)
  • Chen L.Y., Xu T., Wang H., Sang P., Lu S., Ze-Xin Wang Z.X., Chen S. and Zhangb L.C., "Phase interaction induced texture in a plasma sprayed-remelted NiCrBSi coating during solidification: an electron backscatter diffraction study", Surface-Coatings Technology, 358:467-480, (2019)
  • Miguel J.M., Guilemany J.M. and Vizcaino, S., "Tribological study of NiCrBSi coating obtained by different processes", Tribology International, 36(3): 181-187, (2003)
  • Stoica V., Ahmed R. and Itsukaichi T., "Influence of heat-treatment on the sliding wear of thermal spray cermet coatings", Surface-CoatingsTechnology, 199: 7-21, (2005)
  • Carrasquero E.J., Lesage J., Puchi-Cabrera E.S. and Staia M.H., "Fretting wear of HVOF Ni-Cr based alloy deposited on SAE 1045 steel". Surface-CoatingsTechnology, 202: 4544-4551, (2008)
  • Serres N., Hlawka F., Costil S., Langlade C., Machi F. and Cornet A., "Dry Coating sand ecodesign. Part 2. Tribological performances", Surface-CoatingsTechnology, 204(1-2): 197-204, (2009)
  • Habib K.A., Cano D.L., Heredia J.A. and Mira J.S., "Effect of post-coating technique on microstructure, microhardness and the mixed lubrication regime parameters of thermally-sprayed NiCrBSi coatings", Surface-Coatings Technology, 358: 824-832, (2019)
  • Gemalmayan N., "Sürtünme Malzemelerinin Özelliklerinin Deneysel İncelenmesi", Doktora Tezi, Gazi Üniversitesi Fen Bilimleri Enstitüsü, , Ankara, (1984)
  • Halderman J.D., "Automotive brake systems", Second Edition, Prentice-Hall, (2000)
  • Eriksson M., Bergman F. and Jacobson S., "On the nature of tribological contact in automotive brakes", Wear, 252:26-36, (2002)
  • Zhao N., Zhao Y., Wei Y., Wang X., Li L., Xu Y., Yan F. and Lu Z., "Friction and wear behavior of TaC ceramic layer formed in-situ on the gray cast iron", Tribology International, 135:181-188, (2019)

The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc

Year 2020, Volume: 23 Issue: 3, 755 - 761, 01.09.2020
https://doi.org/10.2339/politeknik.563277

Abstract

The movement of moving devices or machines in terms of safety
perspective must be controlled. In modern vehicle applications, braking is
closely related to safety. Slowing or breaking the movements of vehicles safely
is the task of braking mechanisms. The most important components of these mechanisms
are the disc and brake lining pairs. Brake discs are made of lamella graphite
cast iron. During the braking, the kinetic energy of the vehicle is converted
into the heat energy through friction. The braking elements are subject to very
heavy thermo mechanical conditions under heat, speed and load. The friction and
wear properties of the brake disc must be thermally more stable against the
heat energy generated on it in order to maintain stability. In this study,
mechanical properties of the brake discs, which the disc surface was coated
with flame spraying and melting, were improved. In addition, microstructure,
abrasion, hardness and surface roughness tests of the brake disc were
conducted. As a result, the coated disc showed superior mechanical properties
compared to the original disc.

References

  • Mutlu I., Eldogan O. and Fındk F., "Tribological properties of some phenolic composites suggested for automotive brakes", Tribology International, 39:317-325, (2006)
  • Wu Y., Ma Y., Gao W., Yang G., Fu H., Xi N. and Chen H., "High temperature wear performance of laser cladding CoO6 coating on high-speed train brake disc", Applied Surface Science, 481:761-766, (2019)
  • Rachidi R., Kihel B. E. and Delaunois F., "Microstructure and mechanical characterization of NiCrBSi alloy and NiCrBSi-WC composite coatings produced by flame spraying", Materials Science-Engineering, 241:13-21 (2019)
  • Demir A., Samur R. and Kılıçaslan I., "Investigation of the coatings applied onto brake discs on disc-brake pad pair", Metalurgija, 48(3): 161-166, (2009)
  • Wang J., Fu Z.K., Guo J., Zhang Y.Q., Liu Q.Y. and Zhu M.H., "Investigation on wear resistance and fatigue damage of laser cladding coating on wheel and rail materials under the oil lubrication condition". Tribology Transactions, 59(5):810-817, (2016)
  • Wu Y., Liu Y., Chen H., Chen Y., Li H. and Yi W., "Microstructure evolution and crack propagation feature in thermal fatigue of laser deposited Stellite 6 coating for brake discs", Surface-Coatings Technology, 358: 98-107, (2019)7. Zamani P. and Valefi Z., "Microstructure, phase composition and mechanical properties of plasma sprayed Al2O3, Cr2O3 and Cr2O3-Al2O3 composite coatings", Surface-Coatings Technology, 316:138-145, (2017)
  • Poirier D., Legoux J.G., Irissou E., Gallant D., Jian, J., Potter T. and Boileau J., "Performance assessment of protective thermal spray coatings for lightweight al brake rotor disks", Journal of Thermal Spray Technology, 28 (1-2): 291-304, (2019)
  • Güney B. and Mutlu İ., "Tribological properties of brake discs coated Cr2O3-40%TiO2 by plasma spraying", Surface Review And Lettres, (2019)
  • Tucker R.C., "Thermal spray coatings", ASM Handbook, 5:497-509, (1994)
  • Evkaya M., "Metallere aşınmaya karşı yapılan kaplamada uygun toz materyali ve kaplama yönteminin bilgisayar destekli seçimi", Yüksek Lisans Tezi, Marmara Üniversitesi Fen Bilimleri Enstitüsü, İstanbul, (2003)
  • Gonzalez R., Cadenas M., Fernandez R., Cortizo J.L. and Rodriguez E., "Wear behaviour of flame sprayed NiCrBSi coating remelted by flame or by laser", Wear, 262: 301-307, (2007)
  • http://www.ep-coatings.co.uk/processes/flame-spraying/, Received on May 11, 2019
  • Schwartz M., "Encyclopedia of materials", Parts and Finishes 2 nd ed., CRC Pressb LLC, 895, (2002)
  • Salman S., "Plazma ve alev püskürtme tekniğiyle Al2O3-%13TiO2 ve Cr2O3-%5SiO2-%3TiO2 seramik kaplanan malzemelerin özellikleri", Doktora Tezi, Yıldız Teknik Üniversitesi, Fen Bilimleri Enstitüsü, İstanbul, (1995)
  • https://www.oerlikon.com/ecomaXL/files/oerlikon_BRO-0001.17_TS_MaterialGuide_EN.pdf , Received on May 11, 2019
  • Rodrıguez J., Martin A., Fernandez R. and Fernandez J. E., "An experimental study of the wear performance of NiCrBSi thermal spray coatings", Wear, 255: 950-955, (2003)
  • Miguel J.M., Guilemany J.M. and Vizcaino S. "Tribological study of NiCrBSi coating obtained by different processes", Tribology International, 36(3): 181-187, (2003)
  • Hidalgo V.H., Varela F.J.B., Menendez A.C. and Martinez, S.P., "A comparative study of high-temperature erosion wear of plasma sprayed NiCrBSiFe and WC-NiCrBSiFe coatings under simulated coal-fired boiler conditions", Tribology International, 34:161-169, (2001)
  • Ming Q., Lim L.C. and Chen, Z.D. "Laser cladding of nickel - based hardfacing alloys", Surface-Coatings Technology, 106: 174-182, (1998)
  • Wu P., Zhou C. Z. and Tang X. N., "Microstructural characterization and wear behavior of laser cladded nickel-based and tungsten carbide composite coatings", Surface-Coatings Technology, 166:84-88, (2003)
  • Serres N., Hlawka F., Costil S., Langlade C. and Machi F., "Microstructures of metallic NiCrBSi coatings manufactured via hybrid plasma spray and in situ Laser remelting process", Journal of Thermal Spray Technology, 20(1-2):336-343, (2011)
  • Grivc U., Derzic D. and Simon Muhic S., "Numerical optimisation and experimental validation of divided rail freight brake disc crown", Journal of Modern Transportation, 27(1):1-10, (2019)
  • Hong S., Wu Y., Li G., Wang B., Gao W. and Ying, G., "Microstructural characteristics of high-velocity oxygen-fuel (HVOF) sprayed nickel-based alloy coating", Journal of Alloys and Compounds, 581:398-403, (2013)
  • Bergant Z., Trdan U. and Grum J., "Effect of high-temperature furnace treatment on the microstructure and corrosion behavior of NiCrBSi flame-sprayed coatings", Corrosion Science, 88:372-386, (2014)
  • Chen L.Y., Xu T., Wang H., Sang P., Lu S., Ze-Xin Wang Z.X., Chen S. and Zhangb L.C., "Phase interaction induced texture in a plasma sprayed-remelted NiCrBSi coating during solidification: an electron backscatter diffraction study", Surface-Coatings Technology, 358:467-480, (2019)
  • Miguel J.M., Guilemany J.M. and Vizcaino, S., "Tribological study of NiCrBSi coating obtained by different processes", Tribology International, 36(3): 181-187, (2003)
  • Stoica V., Ahmed R. and Itsukaichi T., "Influence of heat-treatment on the sliding wear of thermal spray cermet coatings", Surface-CoatingsTechnology, 199: 7-21, (2005)
  • Carrasquero E.J., Lesage J., Puchi-Cabrera E.S. and Staia M.H., "Fretting wear of HVOF Ni-Cr based alloy deposited on SAE 1045 steel". Surface-CoatingsTechnology, 202: 4544-4551, (2008)
  • Serres N., Hlawka F., Costil S., Langlade C., Machi F. and Cornet A., "Dry Coating sand ecodesign. Part 2. Tribological performances", Surface-CoatingsTechnology, 204(1-2): 197-204, (2009)
  • Habib K.A., Cano D.L., Heredia J.A. and Mira J.S., "Effect of post-coating technique on microstructure, microhardness and the mixed lubrication regime parameters of thermally-sprayed NiCrBSi coatings", Surface-Coatings Technology, 358: 824-832, (2019)
  • Gemalmayan N., "Sürtünme Malzemelerinin Özelliklerinin Deneysel İncelenmesi", Doktora Tezi, Gazi Üniversitesi Fen Bilimleri Enstitüsü, , Ankara, (1984)
  • Halderman J.D., "Automotive brake systems", Second Edition, Prentice-Hall, (2000)
  • Eriksson M., Bergman F. and Jacobson S., "On the nature of tribological contact in automotive brakes", Wear, 252:26-36, (2002)
  • Zhao N., Zhao Y., Wei Y., Wang X., Li L., Xu Y., Yan F. and Lu Z., "Friction and wear behavior of TaC ceramic layer formed in-situ on the gray cast iron", Tribology International, 135:181-188, (2019)
There are 34 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Research Article
Authors

Bekir Güney 0000-0001-9764-9313

İbrahim Mutlu 0000-0001-5563-1000

Hanifi Küçüksarıyıldız 0000-0001-5218-3409

Publication Date September 1, 2020
Submission Date May 13, 2019
Published in Issue Year 2020 Volume: 23 Issue: 3

Cite

APA Güney, B., Mutlu, İ., & Küçüksarıyıldız, H. (2020). The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc. Politeknik Dergisi, 23(3), 755-761. https://doi.org/10.2339/politeknik.563277
AMA Güney B, Mutlu İ, Küçüksarıyıldız H. The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc. Politeknik Dergisi. September 2020;23(3):755-761. doi:10.2339/politeknik.563277
Chicago Güney, Bekir, İbrahim Mutlu, and Hanifi Küçüksarıyıldız. “The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc”. Politeknik Dergisi 23, no. 3 (September 2020): 755-61. https://doi.org/10.2339/politeknik.563277.
EndNote Güney B, Mutlu İ, Küçüksarıyıldız H (September 1, 2020) The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc. Politeknik Dergisi 23 3 755–761.
IEEE B. Güney, İ. Mutlu, and H. Küçüksarıyıldız, “The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc”, Politeknik Dergisi, vol. 23, no. 3, pp. 755–761, 2020, doi: 10.2339/politeknik.563277.
ISNAD Güney, Bekir et al. “The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc”. Politeknik Dergisi 23/3 (September 2020), 755-761. https://doi.org/10.2339/politeknik.563277.
JAMA Güney B, Mutlu İ, Küçüksarıyıldız H. The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc. Politeknik Dergisi. 2020;23:755–761.
MLA Güney, Bekir et al. “The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc”. Politeknik Dergisi, vol. 23, no. 3, 2020, pp. 755-61, doi:10.2339/politeknik.563277.
Vancouver Güney B, Mutlu İ, Küçüksarıyıldız H. The Effect of Flame Spray Coating on the Tribological Properties of Brake Disc. Politeknik Dergisi. 2020;23(3):755-61.