Coated Disc - Manufacture and coating of high-performance rotors using EHLA technology

Road traffic has long been recognised as a major source of air pollution due to emissions of a range of gaseous pollutants, most notably carbon monoxide. However, road transport is also a damaging source of 'non-exhaust emissions' (NEE) particles, which are produced from frictional processes associated with vehicle usage: predominantly from brakes. In contrast to exhaust emissions, which are projected to be significantly reduced with the advent of Electric Vehicles (EVs), NEE arise regardless of the type of vehicle and its mode of power, and contribute to the total ambient particulate matter burden associated with human ill-heath and premature mortality.

Brake dust, emitted during vehicle braking, produces significant amounts of PM10 and PM2.5, i.e. atmospheric particulate matter of diameter less than 10um and 2.5um. Owing to their small size - roughly 5 to 10 times thinner than a human hair - PM2.5 emissions are capable of passing through the human respiratory system and into the lungs. A number of health conditions are linked to their presence, including respiratory illnesses and reduced immunity.

ECOBrakeDisc will address this issue, introducing novelties across the entire brake disc manufacturing supply chain and capitalising on the significant market opportunity. Recent developments in Extreme High-speed Laser Application, a coating technique invented merely three years ago, will introduce a step change in the efficiency and performance of brake disc coatings. Our developments will help the automotive industry in its objective to evolve new brake disc solutions, generating a coating that has a long life, improved surface tribology and interaction with the brake pad, and reduce or eliminate the presence of carcinogenic particles by reducing wear and removing copper, nickel, chromium and cobalt elements. ECOBrakeDisc will drive the development of 4 key new products i) novel powders without harmful elements, ii) methodologies for optimising the EHLA process, iii) route-to-market industrialisation of coated discs using EHLA and iv) new prototype brake discs for validating ECOBrakeDisc approach

The solution is the product of a strategic alliance between Meritor, a leading Tier-1 automotive brakes supplier and global lead in commercial vehicles \>6 tons, ASCO who specialise in precision machining and coating technologies including HVOF, plasma spray and EHLA, and Wall Colmonoy, a world-class coating alloy producer with over 80 years of experience. TWI, who have jointly pioneered significant advancements in EHLA technology, compliment the industrial partners.