Laser cladding treatment for refurbishing disc brake rotors – environmental and tribological analysis

2021 ◽  
Author(s):  
Ulf Olofsson ◽  
Yezhe Lyu ◽  
Anna Hedlund Åström ◽  
Jens Wahlström ◽  
Dizdar Senad ◽  
...  
Keyword(s):  
Cast Iron ◽  
Laser Cladding ◽  
Tribological Performance ◽  
Point Of View ◽  
Grey Cast Iron ◽  
Disc Brake ◽  
Brake Rotor ◽  
Grey Cast ◽  
Tribological Analysis ◽  
Brake Rotors

Abstract In this study, grey cast iron disc brake rotors are refurbished by adding a surface layer through laser cladding. Current methods to deal with replaced rotors mainly include re-melting, with a minority fraction disposed in landfill. Both approaches result in a huge waste of resources and an increase in CO 2 footprint. From a sustainable point of view, this study aims to evaluate the feasibility of refurbishing brake rotors by a combined environmental and tribological performance approach. A streamlined life cycle assessment is conducted to compare the environmental impacts between producing virgin grey cast iron brake rotors and refurbishing replaced brake rotors by laser cladding. It turns out that the energy consumption and CO 2 footprint of the laser cladding refurbished brake rotors are 80% and 90% less than the virgin brake rotors. The results show that the refurbished brake rotor yields higher friction compared to the original cast iron utilizing the same pad material. The wear and particle emissions of the disc brake contact are in this study higher for the laser cladded one compared to the original cast iron one.

scholarly journals Laser Cladding Treatment for Refurbishing Disc Brake Rotors: Environmental and Tribological Analysis

2021 ◽  
Vol 69 (2) ◽  
Author(s):  
Ulf Olofsson ◽  
Yezhe Lyu ◽  
Anna Hedlund Åström ◽  
Jens Wahlström ◽  
Senad Dizdar ◽  
...  
Keyword(s):  
Cast Iron ◽  
Laser Cladding ◽  
Tribological Performance ◽  
Point Of View ◽  
Grey Cast Iron ◽  
Disc Brake ◽  
Brake Rotor ◽  
Grey Cast ◽  
Tribological Analysis ◽  
Brake Rotors

AbstractIn this study, grey cast iron disc brake rotors are refurbished by adding a surface layer through laser cladding. Current methods to deal with replaced rotors mainly include remelting, with a minority fraction disposed in landfill. Both approaches result in a huge waste of resources and an increase in CO2 footprint. From a sustainable point of view, this study aims to evaluate the feasibility of refurbishing brake rotors by a combined environmental and tribological performance approach. A streamlined life cycle assessment is conducted to compare the environmental impacts between producing virgin grey cast iron brake rotors and refurbishing replaced brake rotors by laser cladding. It turns out that the energy consumption and CO2 footprint of the laser cladding refurbished brake rotors are 80% and 90% less than the virgin brake rotors. The results show that the refurbished brake rotor yields higher friction compared to the original cast iron utilizing the same pad material. The wear and particle emissions of the disc brake contact are in this study higher for the laser-cladded one compared to the original cast iron one.

scholarly journals Design and analysis of disc brake system in high speed vehicles

2021 ◽  
Vol 12 ◽  
pp. 19
Author(s):  
Anil Babu Seelam ◽  
Nabil Ahmed Zakir Hussain ◽  
Sachidananda Hassan Krishanmurthy
Keyword(s):  
Stainless Steel ◽  
Cast Iron ◽  
High Speed ◽  
Heat Dissipation ◽  
Optimal Choice ◽  
Grey Cast Iron ◽  
Brake Disc ◽  
Disc Brake ◽  
Brake Rotor ◽  
Grey Cast

Brakes are the most important component of any automobile. Brakes provide the ability to reduce or bring automobile to a complete stop. The process of braking is usually achieved by applying pressure to the brake discs. The main objective of this research paper is to propose an appropriate design and to perform analysis of a suitable brake rotor to enhance the performance of the high-speed car. The design of the brake disc is modelled using Solid works and the analysis is carried out using Ansys software. The analysis has been conducted by considering stainless steel and grey cast iron using same brake rotor design so that optimal choice of brake disc can be considered. The analysis considered involves static structural analysis and steady state thermal analysis considering specific parameters on brake rotor to increase the life of brake rotor. From the analysis it is found that the performance and life of disc brake depends upon heat dissipation. From the analysis results it can be concluded that grey cast iron has performed better as compared to stainless steel as this material has anti-fade properties which improves the life of the brake rotor.

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

2021 ◽  
pp. 135065012110091
Author(s):  
Nicholas Athanassiou ◽  
Ulf Olofsson ◽  
Jens Wahlström ◽  
Senad Dizdar
Keyword(s):  
Cast Iron ◽  
Laser Cladding ◽  
Adhesive Bonding ◽  
Mechanical Performance ◽  
Grey Cast Iron ◽  
Brake Disc ◽  
Particle Emissions ◽  
Brake Discs ◽  
Overlay Welding ◽  
Grey Cast

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.

scholarly journals The Effect of Dynamic Local Self-Preheating in Laser Cladding on Grey Cast Iron

2015 ◽  
Vol 61 (1) ◽  
pp. 43-52 ◽  
Author(s):  
Peng Yi ◽  
Pengyun Xu ◽  
Changfeng Fan ◽  
Chengkai Li ◽  
Yongjun Shi
Keyword(s):  
Cast Iron ◽  
Laser Cladding ◽  
Grey Cast Iron ◽  
Grey Cast

Research on variation and stress status of graphite in laser cladding process of grey cast iron

2013 ◽  
Vol 30 (14) ◽  
pp. 1728-1734 ◽  
Author(s):  
P. Y. Xu ◽  
Y. C. Liu ◽  
P. Yi ◽  
C. F. Fan ◽  
C. K. Li
Keyword(s):  
Cast Iron ◽  
Laser Cladding ◽  
Grey Cast Iron ◽  
Laser Cladding Process ◽  
Grey Cast
Sign in / Sign up

Export Citation Format

Share Document