Lifetime Extension of Rail Brake Discs by Laser Cladding

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There is an ongoing requirement to develop new brake disc solutions for rail vehicles which offer improved frictional performance, longer service life and lower overall mass without hugely increasing the overall cost. This feasibility study will examine the potential of using the laser cladding process to apply novel advanced ceramic particle reinforced metal matrix composite material as an improved frictional wear surface to discs. It will also examine the feasibility of remanufacturing worn discs at the end of their service lifetime and refurbishing them to a standard to allow their re-insertion back into service, coupled with the addition of the improved performance friction cladding. The process will be demonstrated on full size worn discs and a full cost benefit analysis conducted to assess the commercial viability of this approach, which is expected to contribute significant reductions in operational costs and carbon footprint.