Coated Disc - Manufacture and coating of high-performance rotors using EHLA technology

长期以来，道路交通一直被认为是空气污染的主要来源，因为它排放了一系列气体污染物，最明显的是一氧化碳。然而，道路运输也是“非废气排放”（NEE）颗粒的破坏性来源，这些颗粒是由与车辆使用相关的摩擦过程产生的，主要来自刹车。随着电动汽车（ev）的出现，预计废气排放将大幅减少，与此相反，新能源能源的产生与车辆类型和动力模式无关，并导致与人类疾病和过早死亡相关的环境颗粒物总负担。在车辆制动过程中排放的制动粉尘会产生大量的PM10和PM2.5，即直径小于10um和2.5um的大气颗粒物。由于它们的体积很小——大约比人的头发细5到10倍——PM2.5的排放物能够通过人体呼吸系统进入肺部。许多健康状况与它们的存在有关，包括呼吸道疾病和免疫力下降。ECOBrakeDisc将解决这一问题，在整个制动盘制造供应链中引入新产品，并利用重要的市场机会。最近在极高速激光应用的发展，一种涂层技术发明仅仅三年前，将介绍在效率和制动盘涂层性能的一个步骤的变化。我们的发展将有助于汽车行业发展新的制动盘解决方案，产生具有长寿命的涂层，改善表面摩擦学和与刹车片的相互作用，并通过减少磨损和去除铜，镍，铬和钴元素来减少或消除致癌颗粒的存在。ECOBrakeDisc将推动4个关键新产品的开发：1)无有害元素的新型粉末，2)优化EHLA工艺的方法，3)使用EHLA的涂层盘的市场化路线和4)验证ECOBrakeDisc方法的新原型制动盘。该解决方案是美立特战略联盟的产品，美立特是领先的一级汽车制动器供应商和全球领先的商用车产品。ASCO专门从事精密加工和涂层技术，包括HVOF，等离子喷涂和EHLA，以及拥有80多年经验的世界级涂层合金生产商Wall Colmonoy。TWI共同开创了EHLA技术的重大进步，对工业合作伙伴表示赞赏。

Road traffic has long been recognised as a major source of air pollution due to emissions of a range of gaseous pollutants, most notably carbon monoxide. However, road transport is also a damaging source of 'non-exhaust emissions' (NEE) particles, which are produced from frictional processes associated with vehicle usage: predominantly from brakes. In contrast to exhaust emissions, which are projected to be significantly reduced with the advent of Electric Vehicles (EVs), NEE arise regardless of the type of vehicle and its mode of power, and contribute to the total ambient particulate matter burden associated with human ill-heath and premature mortality.Brake dust, emitted during vehicle braking, produces significant amounts of PM10 and PM2.5, i.e. atmospheric particulate matter of diameter less than 10um and 2.5um. Owing to their small size - roughly 5 to 10 times thinner than a human hair - PM2.5 emissions are capable of passing through the human respiratory system and into the lungs. A number of health conditions are linked to their presence, including respiratory illnesses and reduced immunity.ECOBrakeDisc will address this issue, introducing novelties across the entire brake disc manufacturing supply chain and capitalising on the significant market opportunity. Recent developments in Extreme High-speed Laser Application, a coating technique invented merely three years ago, will introduce a step change in the efficiency and performance of brake disc coatings. Our developments will help the automotive industry in its objective to evolve new brake disc solutions, generating a coating that has a long life, improved surface tribology and interaction with the brake pad, and reduce or eliminate the presence of carcinogenic particles by reducing wear and removing copper, nickel, chromium and cobalt elements. ECOBrakeDisc will drive the development of 4 key new products i) novel powders without harmful elements, ii) methodologies for optimising the EHLA process, iii) route-to-market industrialisation of coated discs using EHLA and iv) new prototype brake discs for validating ECOBrakeDisc approachThe solution is the product of a strategic alliance between Meritor, a leading Tier-1 automotive brakes supplier and global lead in commercial vehicles \>6 tons, ASCO who specialise in precision machining and coating technologies including HVOF, plasma spray and EHLA, and Wall Colmonoy, a world-class coating alloy producer with over 80 years of experience. TWI, who have jointly pioneered significant advancements in EHLA technology, compliment the industrial partners.