The development of low particulate emissions coatings for Euro 7-compliant disc brake components

背景：LSN Diffusion是一家气体和水雾化合金粉末的制造商。LSN Diffusion成立于2012年，总部位于南威尔士，向英国供应产品，并出口到欧洲，美国和亚洲。其产品范围涵盖国际标准合金粉末和定制合金粉末，适用于一系列行业的利基应用。LSN将其在粉末雾化方面的丰富经验与专门设计和构建的雾化系统相结合，以适应和满足客户通常独特的化学和颗粒要求。LSN Diffusion拥有一系列国际认证，包括BS EN ISO 9001:2015， BS EN ISO 14001:2015和劳斯莱斯SABRe和GS3001的认证。随着LSN Diffusion进入其运营的第二个十年，包括汽车、增材制造和能源行业在内的许多关键领域都发现了潜在的发展机会。在这些领域的发展将需要LSN Diffusion增加其研发投资和知名度。项目描述：欧盟委员会即将出台的欧7排放标准立法，以确保车辆的排放标准扩展到废气排放之外，因此将对刹车盘等部件的颗粒排放设定限制。值得注意的是，这将适用于包括电动汽车在内的所有车辆，因此将超过当前汽油/柴油设计的使用寿命。在此背景下，本项目将研究环境友好型制动盘部件粉末合金涂层的开发及其在高效激光技术下的应用。这具有广泛的潜力，以减少颗粒排放的刹车部件符合欧7立法。项目组成：-对当前法规和技术进步的初步审查，结合与LSN工业合作伙伴的合作，将确定提供低颗粒制动磨损解决方案所需的潜在合金系统。-为了满足所需的涂层/组件性能，将开发合金系统，随后使用小规模实验室雾化生产粉末批次，然后在LSN的设施中扩展到全尺寸紧密耦合的气/水雾化。-一旦确定并生产出潜在的粉末合金，就可以将制动部件作为激光沉积涂层制造到现有的制动基板上，或者作为定制设计的高构建添加层组件。-一旦成功的工艺/设计交付，将使用基于实验室的技术来评估涂层的磨损性能，包括组件寿命和颗粒排放，以量化和排名涂层性能。

Background:LSN Diffusion is a manufacturer of a gas and water atomised alloy powders. Formed in 2012, LSN Diffusion is based in South Wales and supplies products to the UK and for export to Europe, USA and Asia. It's product range covers international standard alloy powders and bespoke alloy powders for niche applications across a range of sectors. LSN combines is considerable experience of powder atomisation with its suite of purposed designed and constructed atomizing systems to adapt and meet a customer's often unique chemical and particulate requirements. LSN Diffusion holds a range of international certifications including accreditation to BS EN ISO 9001:2015, BS EN ISO 14001:2015 and Rolls Royce SABRe and GS3001. As LSN Diffusion enters its second decade of operations, potential development opportunities have been recognised in a number of key areas, including automotive, additive manufacturing and energy sectors. Advancement in these fields will require LSN Diffusion to enhance its R&D investment and profile.Project Description:The European Commission upcoming Euro 7 emissions standards legislate to ensure that emissions standards for vehicles are extended beyond exhaust emissions and will therefore set limits to particulate emissions from components such as brakes discs. It should be noted that this will apply to all vehicles including electric vehicles and thus will endure beyond the lifetime of current petrol/diesel designs.Against this background, the proposed project will investigate the development of environmentally-friendly powder alloy coatings for brake disc components and their application by high efficiency laser techniques. This has the wide-ranging potential to reduce particulate emissions from brake components in line with Euro 7 legislation. Project Components:- An initial review of the current legislation and technical advances combined with engagement with LSN's industrial partners will identify the potential alloy systems required to deliver a low particulate brake wear solution.- To meet the required coating/component performance, alloy systems will be developed, and subsequent powder batches produced using small-scale laboratory atomisation, followed by scaling to full-scale close-coupled gas/water atomisation in LSN's facility.- Once potential powder alloys have been identified and produced, brake component will be fabricated either as a laser-deposited coating onto an existing brake substrate and/or as a high-build additive layer component of a bespoke design.- Once a successful process/design has been delivered, wear performance of the coating in terms of component life and particulate emission will be assessed using laboratory-based techniques to quantify and rank coating performance.