SK278931B6 - Brake disc and method for producing same - Google Patents

Abstract

The break wheel (1), described in this patent, is created based on the system which has the internal, stationary metal supporting grid (2) or any other similar component, the bars of which (3, 4) are equipped with the abradability resistant layer (5), while the remaining intermediate spaces (6) closed to the supporting grid (2), are filed by light metal and this filling is provided based on the teeming, as for instance. The abradability resistant layer (5) on the supporting grid (2) consits of the layer sprayed based on the thermic spraying which is a suitable procedrue for these approvals.

Description

Technical field

The present invention relates to a brake disc and to a method for its manufacture.

BACKGROUND OF THE INVENTION

Brake discs for cars, trucks, etc. are normally manufactured as one piece of cast iron. Brake discs of less weight but less resistant are also known which are made of aluminum, titanium and their alloys.

The disadvantages of known brake discs are, in the case of cast iron, in their weight, and in the second place light metal brake discs, in terms of comparing the low load potential in terms of heat, corrosion and abrasion and their low mechanical stability.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a brake disc which, on the one hand, has a low weight and, on the other hand, has good properties, such as wear, heat, corrosion and abrasion resistance, as well as mechanical stability.

According to the invention, the problem is solved by a brake disc according to the invention, the principle being that the brake disc is formed by a system having an internal, stable support grid. The bars of this support grid are provided with an abrasion-resistant layer, the remaining intermediate spaces of the support grid being filled with light metal.

The brake disc thus formed has to a large extent the desired properties. In comparison with the known light metal brake discs, its mechanical stability is substantially increased by the support grid. At the same time, good heat dissipation is not impaired by this grid. The abrasion-resistant coating applied to the grating rod contributes, in particular, to an increase in wear resistance and to stability against wear of the brake disc. In addition, filling the intermediate support grid spaces with light metal causes considerable weight compared to cast iron brake discs.

The abrasion-resistant layer preferably consists of a thermally sprayed layer, since the respective deposition methods such as flame spraying and high-speed flame spraying, plasma spraying and arc spraying are fast, economically advantageous deposition methods for wear-resistant surface layers.

The abrasion-resistant layer on the bars of the support grid can in principle consist of a variety of known abrasion-resistant coating materials, for example corresponding steels, molybdenum or layers containing tungsten carbides. Many relevant requirements are largely met by chromium steel layers. Light metals such as aluminum, titanium, or alloys thereof have proven to be suitable filler materials in the intermediate grid spaces of low weight.

A preferred method of manufacturing a brake disc according to the invention consists in presenting a suitably constructed support grid, applying a wear-resistant layer to the support grid bars by a thermal spraying method, preferably by autogenous flame spraying or high-speed flame spraying, and filling the remaining of the support grid by casting the support grid with said light metals. Then, if necessary, it is followed by surface treatment, for example face turning.

Although this method of production imposes some additional costs compared to the production of known brake discs, the construction of the brake disc of several sub-elements and the respective production stages creates the possibility to optimize the properties of the brake disc by varying the corresponding sub-elements and the production method in the desired directions. For example, the abrasion resistance of the formed brake disc can be varied by using different abrasion resistant coatings.

Overview of the figures in the drawing

The invention will be explained in more detail below by way of example with reference to the drawing. A part of the brake disc according to the invention is schematically shown in the accompanying drawing.

DETAILED DESCRIPTION OF THE INVENTION

The quarter of the brake disc 1 shown in the drawing has an inside, dashed, drawn support grid 2. The support grid 2 has a radial rod 3 and concentric rods 4 in the illustrated embodiment. Such a geometry of the support grid 2 is preferably circular-symmetrical 1, however, other geometries of the support grid 2 or carrier are also preferred, for example a rectangular support grid 2 or thin solid discs with lamellas mounted on both sides, spaced apart and arranged perpendicular or also obliquely.

The bars 3, 4 of the support grid 2 or the lamellae are surrounded on all sides, for example by a wear-resistant layer 5 of chrome steel, which is also visible on the surface of the brake disc either after subsequent machining or at least after a certain period of operation. This abraded layer is applied by flame spraying onto a support grid 2, for example according to US-PS 2,861,900, i.e. sprayed chromium steel material is applied to the corresponding surfaces of a stream of combusted acetylene with oxygen, the spray particle velocities being 100 to 100 They are applied at a thickness of preferably 0.5 to 3 mm. The intermediate spaces 6 of the support grid 2, which are not required by the support grid 2 and the wear-resistant layer 5, are filled with aluminum, which is fed in the casting process with the corresponding casting mold into which the support grid 2 with coated struts is inserted. The process of applying the abrasion-resistant layer 5 on the illustrated support grid 2 is preferably carried out in an oblique direction with respect to the central axis of the brake disc and in a variable direction. Thus, even areas of the rods 3, 4 that are on the inner side are coated uniformly and of high value.

The abrasion resistance applied by the abrasion-resistant layer 5 is essentially determined on the brake disks 1 according to the invention, while the abrasion resistance is retained even if the bars 3, 4 of the support grid 2 become loose during prolonged operation. At this stage, the abrasion-resistant material layers provided on the inner side surfaces of the bars 3, 4 of the support grid 2 still act as an abrasion-resistant layer. The support grids 2 are preferably made of sheet metal and have a mesh size ranging from a few millimeters to a range of centimeters. Overall, such brake disks 1 have all the characteristics of high stress brake disks 1 at a comparatively lower weight.

Claims (5)

PATENT CLAIMS Brake disc characterized in that it is formed by a system having an internal, stable metal support grid (2) or the like, the rods (3, 4) of which are provided with a wear-resistant layer (5), the remaining intermediate spaces (6) The support grilles (2) are filled with light metal. Brake disc according to claim 1, characterized in that the wear-resistant layer (5) consists of a thermally sprayed layer. Brake disc according to claim 1 or 2, characterized in that the wear-resistant layer (5) consists of chrome steel. Brake disc according to one of Claims 1 to 3, characterized in that the intermediate spaces (6) of the support grille (2) are filled with a metal such as aluminum, titanium or an alloy thereof. Method for producing a brake disc according to one or more of Claims 1 to 4, characterized in that a suitably constructed, castable support grid is provided, that a wear-resistant layer is applied to the bars of the opposite grid by a thermal spraying method, preferably by autogenous flame spraying; by high-speed flame spraying, and that the remaining intermediate spaces of the coated support grid are filled by embedding the support grid with said light metals, optionally followed by surface treatment.