KR101806636B1 - Dih brake disc and manufacturing method of the same - Google Patents

Dih brake disc and manufacturing method of the same Download PDF

Info

Publication number
KR101806636B1
KR101806636B1 KR1020150174494A KR20150174494A KR101806636B1 KR 101806636 B1 KR101806636 B1 KR 101806636B1 KR 1020150174494 A KR1020150174494 A KR 1020150174494A KR 20150174494 A KR20150174494 A KR 20150174494A KR 101806636 B1 KR101806636 B1 KR 101806636B1
Authority
KR
South Korea
Prior art keywords
coating layer
hat part
casting
spray coating
hat
Prior art date
Application number
KR1020150174494A
Other languages
Korean (ko)
Other versions
KR20170067961A (en
Inventor
정민균
한재민
이윤주
이병찬
이재영
김윤철
Original Assignee
현대자동차주식회사
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 현대자동차주식회사 filed Critical 현대자동차주식회사
Priority to KR1020150174494A priority Critical patent/KR101806636B1/en
Publication of KR20170067961A publication Critical patent/KR20170067961A/en
Application granted granted Critical
Publication of KR101806636B1 publication Critical patent/KR101806636B1/en

Links

Images

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0081—Casting in, on, or around objects which form part of the product pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/08—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02—Anodisation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0007—Casting

Abstract

A first casting step of casting cast iron to provide a main portion; A second casting step of placing a main copper part in a mold and forming a hat part through injection of an aluminum alloy melt to prepare a semi-finished product in which a main body part and a hat part are combined; A step of drawing an intermediate product from a mold and forming an oxide layer on the inner diameter surface of the hat part by soft anodizing; And a coating step of forming a spray coating layer by an arc wire spraying method using a sprayed material on the oxide film layer of the processed hat part.

Description

[0001] DIH BRAKE DISC AND MANUFACTURING METHOD OF THE SAME [0002]

The present invention relates to a DIH brake disk manufacturing method in which an oxide film layer formed by a soft anodizing method is provided between an inner diameter portion at the center of a hat part and a spray coating layer formed by an arc wire method to increase mutual adhesion and improve corrosion resistance.

Generally, a brake device applied to a vehicle includes a foot brake device that provides a braking force to the vehicle by stepping on the foot pedal while the driver is driving the vehicle, and a lever And a parking brake device for braking the vehicle so as not to generate the brake force.

The brake device applied to the vehicle can be classified into a disc brake device and a drum brake device depending on the operating mode.

Among them, the disc brake apparatus is structured such that a disc provided on both sides thereof presses and brakes a disc rotating together with a wheel, and a large number of disc brakes are mounted on the front wheel of the vehicle. The drum brake apparatus includes a drum The brake shoe of the pair extends and brakes, and is mounted on the rear wheel of the vehicle.

At this time, the drum brake device mounted on the rear wheel also serves as a parking brake in addition to the main brake.

In more detail, the drum brake device is connected to a parking brake lever provided in a vehicle interior, so that a brake shoe pulled by a cable when the user operates the parking brake lever is brought into close contact with the brake drum, thereby generating braking force.

Recently, a disc brake is used instead of a drum brake in a rear wheel of a vehicle. When a disc brake is used on a rear wheel, a parking brake is provided separately from a disc brake, which is a DIH (Drum in hat) brake device.

The inner diameter part of the part connected to the main part of the DIH brake device should be a part where mechanical friction with the friction material is generated. Conventionally, such hat parts are mainly made of gray cast iron having excellent heat resistance and abrasion resistance.

However, gray cast iron is a cast iron precipitated in the form of flake graphite, which has excellent mechanical strength, corrosion resistance and vibration absorbability, while its specific gravity is 7.2 g / cm 3, which is considerably heavy and thus deteriorates the ride comfort, operability and fuel economy I had an issue to make.

Recently, due to problems such as depletion of petroleum energy and climate change, the world car industry is required to develop a technology for improving fuel efficiency. Especially, technology for improving fuel efficiency has been attracting attention as a technology for reducing the weight of a vehicle without degrading performance , The DIH brake unit having the disc brake unit and the drum brake unit combined together is heavy in weight compared to the other brake unit, which increases the weight of the vehicle, thereby deteriorating ride comfort, operability and fuel efficiency of the vehicle.

It should be understood that the foregoing description of the background art is merely for the purpose of promoting an understanding of the background of the present invention and is not to be construed as an admission that the prior art is known to those skilled in the art.

KR 10-2011-0034849 A

An object of the present invention is to provide a DIH brake disk manufacturing method in which an oxide film layer formed by a soft anodizing method is provided between an inner diameter portion at the center of a hat part and a spray coating layer formed by an arc wire method to increase mutual adhesion and improve corrosion resistance. have.

According to another aspect of the present invention, there is provided a method of manufacturing a DIH brake disk, including: a first casting step of casting cast iron to provide a main part; A second casting step of placing a main copper part in a mold and forming a hat part through injection of an aluminum alloy melt to prepare a semi-finished product in which a main body part and a hat part are combined; A step of drawing an intermediate product from a mold and forming an oxide layer on the inner diameter surface of the hat part by soft anodizing; And a coating step of forming a spray coating layer by an arc wire spraying method using a sprayed material on the oxide film layer of the processed hat part.

And a preheating step of preheating the main copper part to 400 to 500 ° C so as to improve the flowability and filling property of the aluminum alloy melt after the first casting step.

And a first polishing step of polishing the inner diameter surface of the hat part after the second casting step.

In the first polishing step, the inner part surface roughness (Ra) of the hat part can be polished to be 1.0 to 2.0 占 퐉.

The thickness of the oxide film layer in the processing step may be in the range of 7.0 to 15.0 mu m.

And a processing step of performing a shot blast treatment of the inner diameter portion surface of the hat part having an oxide layer formed thereon by using alumina after the processing step.

In the treatment step, the shot blast treatment can be performed such that the inner diameter portion surface roughness (Ra) of the hat part is 5.0 to 8.0 탆.

In the coating step, the spray material may be a hard wire (HSWR) iron (Fe) wire.

And a second polishing step after the coating step to polish the spray coating layer such that the thickness of the spray coating layer is 100 to 150 占 퐉 and the surface roughness Ra is 0.8 to 1.8 占 퐉.

A DIH brake disc according to the present invention includes: a first casting step of casting cast iron to provide a main molding part; A second casting step of placing a main copper part in a mold and forming a hat part through injection of an aluminum alloy melt to form a semi-finished product in which the main part and the hat part are combined; A step of drawing an intermediate product from a mold and forming an oxide layer on the inner diameter surface of the hat part by soft anodizing; And a coating step of forming a spray coating layer by an arc wire spraying method using a thermal spray material on the oxide film layer of the processed hat part.

The thickness of the oxide film layer may be in the range of 7.0 to 15.0 mu m.

According to the DIH brake disk manufacturing method of the present invention as described above, the oxide coating layer formed by the soft anodizing technique has the effect that the spray coating layer formed by the arc wire spraying method is tightly adhered to the inner diameter surface of the hat part. Further, an effect of further improving the corrosion resistance can be expected.

1 is a perspective view showing a typical DIH brake disk;
2 is a photograph showing a spray coating layer according to a comparative example.
3 is a photograph showing a spray coating layer according to a comparative example.
4 is a photograph showing a spray coating layer according to a comparative example.
5 is a photograph showing a spray coating layer according to a comparative example.
6 is a photograph showing a spray coating layer according to an embodiment of the present invention.

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

A method of manufacturing a DIH brake disk according to the present invention includes: a first casting step of casting cast iron to provide a main body part (100); A second casting step of placing the main copper part 100 on the inside of the mold and forming a hat part 200 through injection of an aluminum alloy melt to prepare a semi-finished product in which the main body part and the hat part 200 are combined; A step of drawing an intermediate product from a mold and forming an oxide layer on the inner diameter surface of the hat part 200 by soft anodizing; And a coating step of forming a spray coating layer by an arc wire spraying method using a thermal spray material on an oxide coating layer of the processed hat part (200).

Generally, a DIH brake disk used in a vehicle is composed of a main body part 100 and a hat part 200, and in particular, an inner diameter part of a hat part 200 in which a friction material (lining) and mechanical friction are generated has excellent wear resistance Is required.

The method of manufacturing a DIH brake disk according to an embodiment of the present invention is characterized in that the main part 100 is made of gray iron and the hat part 200 is made of an aluminum alloy so as to reduce the weight of the vehicle, A spray coating layer is formed on the inner circumferential surface thereof to improve abrasion resistance.

The first casting step is manufactured by casting gray cast iron which is excellent in heat resistance and abrasion resistance and excellent in static friction coefficient and dynamic friction coefficient and is manufactured by gravity casting method, differential pressure casting method, low pressure casting method, vacuum suction casting method, die casting method or squeeze casting method But it is most preferable to apply the sand casting method.

At this time, the main part 100 is formed with a tensile strength of 170 MPa or more, and a plurality of coupling protrusions or the like radially formed on the inner circumferential surface to which the hat part 200 is coupled .

Meanwhile, as an embodiment of the method for manufacturing a DIH brake disk according to the present invention, the preheating step of preheating the core portion 100 of the cast iron material after the first casting step may be further included.

This has the effect of improving the flowability and filling property of the aluminum alloy melt forming the hat part 200. [ In this case, it is preferable that the main body part 100 is preheated to 400 to 500 ° C because it is difficult to secure sufficient flowability and filling property of the aluminum alloy melt when it is preheated to less than 400 ° C, It is possible to cause deformation of the main part 100 and it is limited to 400 to 500 ° C.

When the main body part 100 is provided, the main part 100 and the hat part 200 are positioned inside the mold previously prepared in the second casting step and the hat part 200 is cast, To prepare a semi-finished product.

A variety of casting techniques may be applied to the hat part 200 in the same manner as the main part 100, but it is most preferable that the cast part is manufactured by a gravity casting process or a low-pressure casting process.

More specifically, the aluminum alloy melt used in the hat part casting is preferably 11 to 13 wt% of silicon (Si), 3 to 5 wt% of copper (Cu) , Nickel (Ni): 2 to 4 wt%, and the balance aluminum (Al) and unavoidable impurities.

Accordingly, the hat part 200 is manufactured from an aluminum alloy in place of the gray cast iron in the prior art, thereby reducing the weight of the vehicle and improving the fuel consumption and running operability.

Silicon (Si) improves the mechanical properties such as abrasion resistance of the aluminum alloy during the curing process of the alloy and improves the fluidity of the aluminum alloy melt. When the content of silicon (Si) is less than 11 wt%, the strength And if it is more than 13 wt%, the strength is improved but the elongation rate is rapidly lowered and the brittleness is increased, so that it is preferable to limit it to 11 to 13 wt%.

On the other hand, copper (Cu) improves the corrosion resistance and mechanical properties of aluminum alloys by inducing solid solution strengthening effect. When the content is less than 3 wt%, the solid solution strengthening effect is not sufficient and corrosion resistance and mechanical characteristics are not sufficiently improved. %, There is a problem that the casting of the alloy is lowered, so that it is limited to 3 to 5 wt%.

Also, nickel (Ni) is formed of aluminum and intermetallic compounds, and improve the high temperature properties of an aluminum alloy, with an element that serves to enhance the main composition, if the content of Ni-2wt% less than metal, such as Al 3 Ni liver It is impossible to secure sufficient high-temperature characteristics and castability. When the amount of the nickel compound exceeds 4 wt%, the intermetallic compound becomes coarse to increase the brittleness of the aluminum alloy. Therefore, the content of nickel is limited to 2 to 4 wt% desirable.

As an embodiment of the DIH brake disk manufacturing method according to the present invention, after the semi-finished product in which the main part 100 and the hat part 200 are combined as described above after the second casting step is prepared, And a first polishing step of polishing the neck surface.

In this case, the first polishing step is to perform roughing and turning after omitting the honing process in the polishing process of conventional roughing → turning (finishing) → honing (grinding) process, and the surface roughness (Ra) In order to further increase the adhesion of the coating layers to be coated onto the inner diameter portion surface of the hat part 200 thereafter.

On the other hand, in the machining step, the semi-finished product is taken out from the mold and subjected to soft anodizing to form an oxide coating layer on the inner diameter surface of the hat part 200.

The anodizing technique is divided into a soft anodizing technique and a hard anodizing technique. The anodized layer formed by the soft anodizing is thin and has a low hardness. However, it has an advantage that it is easy to prevent corrosion of the aluminum alloy and has ductility. The coating layer is thicker than the soft layer and has a high hardness, but it has no ductility and is vulnerable to corrosion prevention.

Therefore, as will be described later in detail, the method for manufacturing a DIH brake disk according to the present invention forms an oxide coating layer using a soft anodizing technique because it is an object of improving the corrosion resistance excellent in corrosion prevention by forming an oxide coating layer using anodizing.

As an embodiment of the method of manufacturing a DIH brake disk according to the present invention, the method further includes a step of performing a shot blast treatment of the inner diameter portion surface of the hat part 200 having an oxide coating layer formed thereon after the step of forming an oxide layer, using alumina .

The inside and the side portions of the main body part 100 are masked and then shot blasted by using alumina powder or the like to increase the bonding area of the coating layer to be coated on the oxide film layer to improve the bonding force. At this time, it is preferable that the surface roughness (Ra) is 5.0 to 8.0 占 퐉 in a shot blast treatment because if the coating strength is less than 5.0 占 퐉, the bonding force of the coating layer to be coated is lowered and if it is more than 8.0 占 퐉, It is because.

On the other hand, a spray coating layer is formed by an arc wire spraying method using a sprayed material over the oxide film layer.

At this time, the spray coating layer is formed using iron (Fe), but various metals having excellent abrasion resistance, heat resistance and vibration absorbability can be selectively applied.

The hardness (HV) of the spray coating layer is preferably 300 to 400 HV. If the hardness exceeds 400HV, the relative aggressiveness increases, which can cause excessive wear and noise of the friction material such as lining. When the hardness is less than 300HV, the wear amount of the spray coating layer increases. Therefore, the hardness (HV) 400 HV.

The formation of the spray coating layer by the flame wire spraying method is advantageous in that the manufacturing cost can be reduced because the process cost is low, but the adhesion speed between the neck portion and the spray coating layer in the hat part 200 in which the oxide film layer is formed, There is a degradation problem. When the spray coating layer is formed by the plasma wire spraying method, the particle velocity of the molten particles is secured, but the temperature of the molten particles is excessively high and the temperature is the highest, which may lead to disc thickness variation (DTV) and poor run out I have a problem.

Therefore, in the method of manufacturing a DIH brake disk according to the present invention, a spray coating layer is formed on the oxide layer of the inner diameter portion of the hat part 200 by an arc wire spraying method. In the case of the arc wire spraying method, since the particle velocity of the molten particles is high and the energy of the particles is high, the spray coating layer is tightly adhered to the neck portion of the hat part 200 in which the oxide coating layer is formed.

This can be confirmed by the following Table 1.

Anodizing Adherence of spray coating layer Kinds Thickness (㎛) Hardness (HV) Flame Wire Wires Arc wire Soft
3.0 150 OK OK 7.0 150 OK OK reshuffle
20 400 NG OK 33 400 NG OK

As can be seen from Table 1, when the spray coating layer was formed on the oxide coating layer formed by the soft anodizing technique and the hard anodizing technique by the arc wire spraying method, there was no problem in the adhesion state of the spray coating layer, and the oxide coating layer formed by the soft anodizing technique Even when the spray coating layer is formed by the wire spraying method, there is no problem in the adhesion state of the spray coating layer. However, when the spray coating layer is formed by the flame wire spraying method on the oxide coating layer formed by the hard anodizing technique, The coating layer of the spray was cracked or floated.

This is because the hardness of the oxide film layer formed by the hard anodizing technique is so high that the molten particles are not firmly adhered to the surface, and in the case of the flame wire spraying method as mentioned above, the phenomenon that the particle velocity of the molten particles is slow, The problem of adhesion of the spray coating layer is generated.

In an embodiment according to the present invention, the thickness of the oxide coating layer may range from 7.0 to 15.0 占 퐉. The reason for limiting the thickness of the oxide film layer to the range of 7.0 to 15.0 탆 is as follows. When the thickness of the oxide film layer is less than 7.0 mu m, the oxide film layer remaining after the shot blasting treatment or the spray coating treatment is thin, making it difficult to secure the corrosion resistance. When the thickness of the oxide film layer exceeds 15.0 mu m, the hardness is increased and the adhesion force is lowered, so that the thickness of the oxide film layer is limited to 7.0 to 15.0 mu m.

The effect of the limitation can be confirmed by the following Tables 2 and 3.

Anodizing Adherence of spray coating layer Kinds Thickness (㎛) Hardness (HV) Flame Wire Wires Arc wire Soft
3.0 150 NG NG 7.0 150 NG OK reshuffle
20 400 - NG 33 400 - NG

Anodizing Thickness of oxide film layer remaining after spray coating (占 퐉) Kinds Thickness (㎛) Hardness (HV) Flame Wire Wires Arc wire Soft
3.0 150 0 to 0.74 0 to 1.91 7.0 150 0 to 0.65 3.02 to 5.52 reshuffle
20 400 - 1.14 to 1.62 33 400 - 1.26 ~ 1.73

In Table 1, six DIH brake discs which had no problem in close contact state were put into the salt spray chamber for about 120 hours, and the adhesion state of the spray coating layer was confirmed. As shown in FIG. 3, when the spray coating layer was formed by the flame wire spraying method on the oxide coating layer formed by the soft anodizing technique, the spray coating layer was broken regardless of the thickness of the oxide coating layer.

This is because, as mentioned above, the adhesion of the flame wire spraying method is weak enough to withstand brine spraying as compared with the arc wire spraying method because of the particle velocity of the molten particles.

In addition, even when the spray coating layer is formed by the arc wire spraying method on the oxide layer formed by the hard anodizing technique, the adhesion is not good enough to withstand salt spray due to the characteristics of the hard oxide layer. This fact can be confirmed that the spray coating layer is cracked as shown in FIG.

On the other hand, a spray coating layer was formed by an arc wire spraying method on the oxide layer formed by the soft anodizing technique. Even when the thickness of the spray coating layer was less than 7.0 탆 and 3.0 탆, the spray coating layer was lifted as shown in FIG. As can be seen from Table 3, it was difficult to secure the corrosion resistance because the remaining oxide layer was thin after the spray coating layer was formed by the arc wire spraying method.

When the thickness of the spray coating layer was 7.0 탆, the spray coating layer was formed by the arc-wire spraying method as shown in Table 3, and the remaining anodic coating layer was 3.02 To 5.52 占 퐉, which is excellent in corrosion resistance, so that the state in which the sprayed coating layer is adhered as shown in Fig. 6 can be maintained.

Conventionally, in order to enhance corrosion resistance, a method of sealing a spray coating layer was used in connection with the excellent corrosion resistance in the case of forming a spray coating layer by an arc wire spraying method on an oxide coating layer using a soft anodizing technique. In this case, the sealing material is mainly used as an epoxy-based polymer material, and the sealing process is performed by a method of curing the same. In this case, it may be effective to improve the corrosion resistance, but if the friction coefficient is lowered, if the continuous corrosion occurs, the face aggressiveness is increased.

This can be confirmed by the following Table 4.

Coefficient of friction Evaluation of friction and wear after 120 hours of salt spray Production (FC170D) 0.38 4 times braking only Lining pre-wear Soft oxide layer + arc spray coating layer 0.38 Approximately 20% wear after lining 200 times braking Spray coating layer + sealing treatment 0.30 20 times braking only Lining pre-wear

In the case of forming the spray coating layer by the arc wire spraying method on the oxide film layer using the soft anodizing technique, the coefficient of friction is higher than the case of sealing the spray coating layer, and unlike the case where the lining is completely worn in the braking operation of 20 times, The wear resistance of the lining was only about 20%, and the corrosion resistance was improved.

Preferably, the sprayed material used for forming the spray coating layer may be a high carbon steel wire rod (HSWR) iron (Fe) wire having a carbon content of 0.44 wt% or more, (S): 0.44 to 0.51 wt%, silicon (Si): 0.15 to 0.35 wt%, manganese (Mn): 0.60 to 0.90 wt% : 0.04 wt% or less, and the balance iron (Fe) and unavoidable impurities.

In this case, when the carbon content of the steel wire material is less than 0.44 wt%, it is preferable to form the spray coating layer by using a hardened steel wire having a carbon content of 0.44 wt% or more because the heat radiation property and the lubricating property are lowered and the wear resistance may be lowered.

The method of manufacturing a DIH brake disk according to the present invention may further include a second polishing step after the coating step so as to satisfy the thickness and surface roughness of the spray coating layer required in the final product.

At this time, it is preferable to polish the spray coating layer such that the thickness of the spray coating layer is 100 to 150 탆 and the surface roughness (Ra) is 0.8 to 1.8 탆.

If the thickness of the spray coating layer is less than 100 탆, the thickness of the spray coating layer is thin, and the replacement cycle can be shortened according to the wear. If the thickness exceeds 150 탆, the manufacturing cost is increased but the abrasion resistance is not greatly improved. When the thickness is less than 0.8 탆, the friction coefficient can not be sufficiently secured and the braking force of the vehicle can be lowered. If it exceeds 1.8 탆, the wear of the friction material may be accelerated.

The DIH brake disk according to the present invention includes a first casting step of casting cast iron to provide a main molding part 100; A second casting step of placing the main molding part 100 in the mold and forming the hat part 200 through injection of the molten aluminum alloy to form a semifinished product in which the main tub part and the hat part 200 are combined; A step of drawing an intermediate product from a mold and forming an oxide layer on the inner diameter surface of the hat part 200 by soft anodizing; And a coating step of forming a spray coating layer on the oxide coating layer of the processed hat part 200 by using an arc wire spraying method using a sprayed material.

In this case, the thickness of the oxide film layer may be in the range of 7.0 to 15.0 탆.

While the present invention has been particularly shown and described with reference to specific embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the following claims It will be apparent to those of ordinary skill in the art.

100: Motif part 200: Hat part

Claims (11)

A first casting step of casting cast iron to provide a main portion;
A second casting step of placing a main copper part in a mold and forming a hat part through injection of an aluminum alloy melt to prepare a semi-finished product in which a main body part and a hat part are combined;
A step of drawing an intermediate product from a mold and forming an oxide film layer having a thickness of 7.0 to 15.0 탆 on the inner diameter surface of the hat part by soft anodizing;
A step of performing a shot blast treatment of the inner diameter portion surface of the hat part having the oxide film layer formed thereon using alumina; And
And a coating step of forming a spray coating layer by an arc wire spraying method using a sprayed material on the oxide layer of the processed hat part. The method according to claim 1,
After the first casting step,
Further comprising a preheating step of preheating the main copper part to 400 to 500 DEG C so as to improve the flowability and filling property of the aluminum alloy melt. The method according to claim 1,
After the second casting step,
Further comprising a first polishing step of polishing the inner diameter surface of the hat part. The method of claim 3,
Wherein in the first polishing step, polishing is performed so that the inner diameter portion surface roughness (Ra) of the hat part becomes 1.0 to 2.0 占 퐉. delete delete The method according to claim 1,
Blast treatment is performed so that the inner diameter portion surface roughness (Ra) of the hat part is 5.0 to 8.0 占 퐉 in the treatment step. The method according to claim 1,
Wherein the spray material in the coating step is a hard steel wire (HSWR) iron (Fe) wire. The method according to claim 1,
After the coating step,
Further comprising a second polishing step of polishing the spray coating layer such that the thickness of the spray coating layer is 100 to 150 占 퐉 and the surface roughness Ra is 0.8 to 1.8 占 퐉. A first casting step of casting cast iron to provide a main portion;
A second casting step of placing a main copper part in a mold and forming a hat part through injection of an aluminum alloy melt to form a semi-finished product in which the main part and the hat part are combined;
A step of drawing an intermediate product from a mold and forming an oxide film layer having a thickness of 7.0 to 15.0 탆 on the inner diameter surface of the hat part by soft anodizing;
A step of performing a shot blast treatment of the inner diameter portion surface of the hat part having the oxide film layer formed thereon using alumina; And
And a coating step of forming a spray coating layer by an arc wire spraying method using a sprayed material over the oxide layer of the processed hat part.
delete
KR1020150174494A 2015-12-08 2015-12-08 Dih brake disc and manufacturing method of the same KR101806636B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
KR1020150174494A KR101806636B1 (en) 2015-12-08 2015-12-08 Dih brake disc and manufacturing method of the same

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
KR1020150174494A KR101806636B1 (en) 2015-12-08 2015-12-08 Dih brake disc and manufacturing method of the same

Publications (2)

Publication Number Publication Date
KR20170067961A KR20170067961A (en) 2017-06-19
KR101806636B1 true KR101806636B1 (en) 2017-12-08

Family

ID=59279291

Family Applications (1)

Application Number Title Priority Date Filing Date
KR1020150174494A KR101806636B1 (en) 2015-12-08 2015-12-08 Dih brake disc and manufacturing method of the same

Country Status (1)

Country Link
KR (1) KR101806636B1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115044859A (en) * 2022-06-17 2022-09-13 中国船舶重工集团公司第七二五研究所 Titanium alloy material surface treatment method

Also Published As

Publication number Publication date
KR20170067961A (en) 2017-06-19

Similar Documents

Publication Publication Date Title
KR101856288B1 (en) Drum in hat brake disk for vehicle and manufacturing method thereof
US9879740B2 (en) Method for making a brake disc, brake disc for disc brake and a disc brake
US11635117B2 (en) Process for producing a protective coating on a brake side of a brake disk main element and process for producing a brake disk
US10288136B2 (en) Brake disc coating made from an iron alloy composition and method for the production thereof
JP2010156003A (en) Cast-iron member with cast-in spray deposit film, method for manufacturing the same, cylinder liner with cast-in spray deposit film, and wear-resistant ring with cast-in spray deposit film
KR20220123063A (en) Brake disc provided with protection against wear and corrosion and method for manufacturing same
CN105556005A (en) Method for producing a brake disk, and brake disk
KR101806636B1 (en) Dih brake disc and manufacturing method of the same
CN111394682A (en) Brake disc and method for producing same
CN107649658B (en) Preparation process of aluminum alloy cylinder sleeve
CN210128033U (en) Automobile brake disc and vehicle
EP4092287A1 (en) Brake body and brake device
US20210199167A1 (en) Disc brake
JP5705553B2 (en) Shot peening method with excellent projectile life
KR102029507B1 (en) Forming mold for flat glass
WO2014178367A1 (en) Shot peening method with which high compressive residual stress is obtained
JPS6233730A (en) Wear resistant composite material
CN112855808A (en) Production process of special steel and thermal fatigue resistant nano material composite brake drum
KR101890148B1 (en) Method of manufacturing a bi-layered friction machine parts made of wear resistant copper alloy having high strength
TWI488765B (en) Wear-resistance brake piston of aluminum alloys and method thereof
JPH07310588A (en) Piston for internal combustion engine and its manufacture
CN105583240B (en) A kind of manufacturing method extending guide plate service life
CN114959692B (en) Ultrahigh-speed laser cladding composite coating brake disc and preparation method and application thereof
JPH08253852A (en) Formation of wear resistant film onto aluminum alloy substrate
JP6313709B2 (en) Method for manufacturing a bearing shell for a sliding bearing

Legal Events

Date Code Title Description
A201 Request for examination
E902 Notification of reason for refusal
GRNT Written decision to grant