Fine dust and CO₂ emissions from road traffic are now held responsible as a major source of environmentally-related health damage. According to the latest statistics from the Federal Motor Transport Authority, around 66.9 million vehicles will be registered in January 2021. In addition to tire wear and vehicle propulsion, brake disc abrasion in particular has a very strong influence on particulate matter and CO₂ emissions in road traffic. Hard-coated brake discs can make a significant contribution to reducing particulate matter and CO₂ emissions in road traffic and increasing service life. With the innovative and environmentally friendly hard coating for brake discs, we have industrialized a revolutionary process that not only significantly reduces particulate emissions but also ensures long-lasting product quality. At the same time, these low-wear brake systems offer lightweight construction potential: weight savings of approx. 20-25% can be achieved by significantly reducing wear allowances, optimized heat dissipation and reduced undamped masses.
Until now, hard-coated brake discs have been manufactured by thermal spraying. Environmental impacts result in particular from the very high energy consumption and the fuels used, such as kerosene. In addition, there is a process-related material loss of approx. 45%. Furthermore, there is no metallurgical bond to the base material in this process. Our hard coating process for brake discs is based on a further development of laser buildup welding and enables the economical production of customized wear and corrosion protection coatings on conventional brake discs in large series in several process steps.
Laser buildup welding can be used to apply a corrosion protection layer to a workpiece, such as a conventional brake disc. This also has a material bond to the workpiece in contrast to conventional corrosion protection methods.
The wear protection layer is also applied highly efficiently using an optimized laser buildup welding process. A wide range of material combinations can be implemented to meet the most diverse customer requirements.
We grind the coated brake disc to the required shape and position tolerances and surface quality in accordance with customer requirements. This is done with the help of double-sided kinematics and a special diamond grinding process.
The central element of our process chain for the industrial hard coating of workpieces is quality control. Here, the focus is on comprehensive in-process monitoring as well as follow-up final quality control. Inline process monitoring includes, for example, melt bath monitoring. In the final quality control, compliance with the drawing tolerances from the finishing process is checked. A random metallurgical examination of the layer quality is also part of the final control.
As an expert in serial hard coating for brake discs, we offer you the entire production as a service. From consulting on the selection of the perfect coating system for your application to the production of prototypes for the most diverse test setups to highly automated series production, we are there for you. We are your partner from development to the end-of-line of your brake disc production.