Reducing emissions, increasing comfort: Optimizing alumina coatings on electric vehicle brake rotors

非废气排放（NEE），如制动粉尘，占所有车辆颗粒物排放量的近一半。在成功实施限制尾气排放的政策后，立法者现在将注意力转向刹车排放。已经提出的减少制动器磨损颗粒的技术包括再生制动、制动盘涂层和新的制动片配方。然而，这些技术是昂贵的，并且再生制动实际上可能导致更大的转子腐蚀。该项目将开发和实施一种称为PEA（等离子体电解铝）的具有成本效益的涂层技术，以减少NEE并提高制动盘的耐腐蚀性。将在部件级别进行各种制动测功机测试，然后进行车辆级别测试。氧化铝基涂层将产生替代的磨损和摩擦机制，其在每次制动事件期间提供更一致的摩擦力并减少粘滑问题，以获得更好的驾驶舒适性和调节。涂层制动系统有望减少制动距离，保持轮辋更清洁。涂层转子将显示出最小的磨损，可能与乘用车的典型寿命相匹配。因此，拟议的制动盘氧化铝涂层技术以及工业合作伙伴新配制的制动片不仅旨在通过减少NEE来改善空气和水质，还将提高骑手的舒适性并减少浪费，从而为电动汽车带来更安全，更可持续的未来。该项目将帮助汽车原始设备制造商和供应商更接近生产“真实的”零排放汽车，实现人人享有电动汽车的目标。

Non-exhaust emissions (NEE), such as brake dust, represent nearly half of all vehicle particulate matter emissions. Having successfully implemented policies limiting tailpipe exhaust emissions, legislators are now turning their attention towards brake emissions. Technologies that have been proposed to reduce brake wear particulates include regenerative braking, disc coatings, and new pad formulations. However, these techniques are expensive, and regenerative braking can actually lead to greater rotor corrosion. This project will develop and implement a cost-effective coating technology, called PEA (plasma electrolytic aluminating), to reduce NEE and increase corrosion resistance of brake rotors. Various brake dynamometer tests will be conducted at component levels, followed by vehicle-level tests. The alumina-based coating would result in an alternative wear and friction mechanism that delivers more consistent friction forces and decrease stick-slip problems during each brake event for better driving comfort and modulation. The coated brake system is expected to reduce braking distance and keep wheel rims much cleaner. The coated rotors would show minimum wear potentially to match a typical lifespan of a passenger car. Thus, the proposed alumina coating technology for brake rotors together with newly formulated brake pads from an industrial partner will target to not only improve air and water quality through NEE reduction, but also promote rider comfort and reduce waste, leading to a safer and more sustainable future for electric vehicles. This project will assist auto OEMs and suppliers to get closer to producing "real" emission-free vehicles towards the goal of electromobility for everyone.