10181885Low-cost Resource Efficient Hardfacing for Brake DiscClosedCollaborative R&DInnovate UKThe project will develop a cost-effective, resource-efficient hard-facing coating solution for coated brake discs to meet the strict Euro 7 emissions limits. To reduce brake dust, brake disc manufacturers have been working with universities and research institutes to develop viable solutions. Among them, tungsten carbide-based (WC) coating deposited using laser Directed Energy Deposition (L-DED) process has found to be most effective. To overcome the high cost and supply instability of WC, titanium carbide-based (TiC) coatings were subsequently developed which is 40-50% cheaper than WC. However, the coated brake disc is still cost 5-6 times more than a cast-iron brake disc. Using Powderloop proprietary powder manufacturing technology and low-cost, abundant materials, the process can produce spherical, free-flowing powder for use in a typical L-DED equipment. The coating process is innovative; during L-DED process, the chemical reaction between the powder constituents leads to in-situ hard phases precipitation from within the melt-pool. The finely distributed hard phases improve the coating's hardness and fracture toughness, which enhance its wear resistance. The project will consider several raw materials to develop hard phases that meeting the Euro 7 emission requirements. The project outcomes, while focusing on the brake disc coating, can be applied to other additive manufacturing and powder metallurgy processes that require high wear resistance and low friction, for both primary manufacturing and repairs. Success in the project will strengthen the UK's supply chain resilience and drive the multi-billion-pound hard-facing sector towards greener and sustainable materials.