As the automotive industry transitions towards cleaner and more sustainable practices, the detrimental environmental impact of brake dust and corrosion in electric vehicles has become a critical concern. To tackle these challenges, cutting-edge solutions have emerged such as High-speed laser cladding and the use of carbide-reinforced powder. Metco Joining and Cladding has pioneered the development of family of MetcoBrake powders. The MetcoBrake9501A, demonstrates efficacy across a spectrum of applications, from small to medium-sized vehicles as a single layer solution with a specific emphasis on addressing the unique demands of the burgeoning e-mobility sector.

Furthermore, brake disc coating solution involves application of double-layer coatings. The bottom coat, incorporating MetcoBrake9501A or MetcoAdd316L, provides an initial protective layer, while the topcoat, featuring MetcoAdd316L with WC or recently developed MetcoBrake9601A-TiC, a novel approach to have a single powder (hard phase encapsulated in matrix particles), adds an extra level of resilience. This double-layer strategy is particularly suited for higher inertia applications, such as performance and commercial vehicles, where elevated durability and enhanced braking performance are paramount.

This study meticulously evaluates the characteristics of different materials used in the coating process. Test results for above mentioned coating solutions are presented, offering valuable insights into their effectiveness in reducing fine dust emissions and mitigating corrosion in electric vehicles. A comparative study is also discussed between single layer solution with MetcoBrake 9501A and FNC with respect to corrosion performance and friction. The outcomes of this research contribute significantly to the ongoing efforts in developing sustainable and regulatory-compliant brake systems, particularly crucial in the context of advancing e-mobility technologies and meeting stringent environmental standards.

Currently braking industry is facing a massive challenge from the regulatory body to reduce brake system non-exhaust fine dust particles. With this imminent regulation it is imperative to investigate solutions which fulfills current regulatory requirements without compromising on the performance aspects of brake system. Alternative solutions like ceramic brake discs are unthinkable in terms of higher cost and longer development cycle. Currently, the focus is on high-speed laser cladding solution with carbide reinforced powder on the brake disc. The challenge in developing such a cladding solution is multifold as there are many options of carbides and matrix materials, also the coating process optimization shall not be overlooked. From a pad development perspective, it is also complicated as we require a coating optimized formulation since the friction pair on the discs is unprecedented. Metco joining and cladding with TMD friction work together to develop right friction pair to reduce fine dust emission without compromising the performance requirements. This paper describes the comparison between a series brake system and Metco coated brake disc with TMD’s optimized pad solution for a famous high range vehicle application. The results will be discussed for both the system with respect to the performance aspects through AK master test and the corresponding improvement in fine dust emission through Euro7 PMP group recommended WLTP cycle.

Laser cladding technology has been identified as one of the most promising technologies in brake disc coating and reducing the particle emission problem from brake discs. It can provide corrosion and wear resistance as well as a very high mechanical resistance through metallurgical bonding with the substrate. In addition to the technical advantages, laser cladding technology brings economic and supply chain advantages. The process efficiency is higher than 90% and is suitable for the scaling up and industrialization phase. The developed materials used in the laser cladding process are cost-effective, and the process requires minimal masking or preparation. It can also be fully automated using robots and set production lines. In this regard, we have developed a single-layer solution, i.e. DiscCover® Beam using a dedicated laser cladding powder for brake disc application, i.e. Metco®Brake powder. The developed powder is perfectly weldable on cast iron substrates without any pre-processing or pre-heating. From the application development point of view, the developed solution for brake disc coating has technical and quality advantages compared to other coating technologies. First, it can provide the required corrosion and wear resistance over such a thickness of 150-300 µm as a single-layer solution. Secondly, it can produce a coating with minimal heat input and carbon pick up from the substrate resulting in deformation in the disc and cracking in the coating. Finally, it also enables good metallurgical bonding with the substrate which guarantees no coating delamination during the operation. In regard to industrialization for mass production scenarios, the economic advantages of laser cladding technology are far ahead of the competing technologies as well. The process can be scaled up with more laser power, higher process speeds, and powder flow rates in addition to possible innovative machine designs to shorten the coating cycle time. These features are ideal for continuous processes. Present work is intended to provide up-to-date information on the latest trends in laser cladding technology on brake discs from application development to industrialization for mass production scenarios.