Performance Assessment of Protective Thermal Spray Coatings for Lightweight Al Brake Rotor Disks
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Performance Assessment of Protective Thermal Spray Coatings for Lightweight Al Brake Rotor Disks Dominique Poirier1 • Jean-Gabriel Legoux1 • Eric Irissou1 • Danick Gallant2 Jimmy Jiang3 • Tim Potter4 • James Boileau4
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Submitted: 20 June 2018 / in revised form: 19 October 2018 / Published online: 26 November 2018 ASM International 2018
Abstract This paper presents the results of a study to evaluate stainless steel thermal spray coatings on aluminum-based substrates. Coating wear, corrosion, and thermal cycling resistance were evaluated using pin-ondisk, cyclic corrosion, and a custom laser-based heating system, respectively, for 300-series stainless steel coatings deposited by arc-sprayed and cold-sprayed systems. Arc spray coatings were found to have equivalent wear and frictional performance as compared to gray cast iron (wear rates of 0.730-1.524 versus 1.294 9 10-5 mm3/m, COF of 0.35-0.36 versus 0.36). However, arc spray coating exhibited low adhesion (* 30 MPa) and early spalling under thermal cycling conditions, i.e., \ 600 cycles, as well as corrosion and delamination. The cold-sprayed coatings were found to have high corrosion and thermal cycling resistance, i.e., above 10,000 cycles. However, cold-sprayed coatings exhibited wear rates higher than those of the cast iron (cold spray wear rates of 4.774 9 10-5 mm3/m). A duplex coating composed of a
This article is an invited paper selected from presentations at the 2018 International Thermal Spray Conference, held May 7-10, 2018, in Orlando, Florida, USA, and has been expanded from the original presentation. & Dominique Poirier [email protected] 1
National Research Council of Canada, 75 de Mortagne Blvd., Boucherville, QC J4B 6Y4, Canada
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National Research Council of Canada, 501 Universite´ Est Blvd., Chicoutimi, QC G7H 8C3, Canada
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National Research Council of Canada, 4250 Westbrook Mall, Vancouver, BC V6T 1W5, Canada
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Ford Motor Company, MD 3135 RIC Building, P.O. Box 2053, Dearborn, MI 48121-2053, USA
cold-sprayed bond coat and an arc-sprayed top coat was created and showed good wear properties under simulated extreme braking conditions. The results from this study show that stainless steel coatings on aluminum substrates could be viable substitute for the cast iron in future brake rotors. Keywords automotive applications cold spray corrosion cyclic heating wear
Introduction In the last two decades, the automotive industry has been facing decreasing the weight of its vehicles as a way to reduce fuel consumption as well as the associated emissions (Ref 1). As a consequence, there has been a trend toward the use of lightweight material assemblies that benefit from the low density of light metals while maintaining the desirable mechanical properties of high strength materials like steels (Ref 2). In automotive mass manufacturing, thermal spray has become a very promising technology to create protective coatings for lightweight metal parts as it is generally low cost, can easily be incorporated into integra
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