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Innovative Coatings for Brake Disks

AM Coating's extraction device protects the laser against contamination and operating personnel against exposure.

Advantage of the process for a high coating speed: the powder particles melt in the laser beam.

"How can the protective layer be applied to the brake disk more quickly and more effectively? And how can it be made to stay on for longer? The solution is intelligent coatings, as can be applied to brake disks using our AM coating system," said Dr. Géza Koscsák, Head of Additive Manufacturing (AM) at the CHIRON Group. He has played a prominent role in developing the new system and reaching the decision to opt for the high-speed deposition welding process in his previous job as head of advanced development.

"Compared with the conventional LMD process, powder particles travel a longer distance before they are applied during high-speed laser material deposition," said a spokesperson. "This means that they absorb more energy and melt in the laser beam, which enables a significantly faster coating speed. This process also has a clear advantage in comparison to thermal coating using high-velocity oxygen fuel spraying."

AM Coating TWIN is specifically designed for series production. The system works with two lasers for front and rear coating, and the brake disks are transferred automatically.

AM Coating SINGLE is suited for those who like to test materials and material combinations in parallel with or before series production, to develop the application process or to manufacture small series. Upon request, the team of experts at the CHIRON Group can provide support during process development, either at the customer premises or in Germany. "We could install a base machine here," said Dr. Koscsák, outlining a potential scenario, "where the customer's specialists can learn the process, run tests and set up the parameters with us ready for series production. Or, for a continuous and even more productive process, we can integrate a grinding machine and perfectly coordinate both systems."

"Of course, productivity is not enough on its own," said Project Manager Ernest Frombach. "The quality of the coatings needs to be right too. What about crack formation and durability? We use high-speed laser material deposition to achieve improved adhesion through the firmly bonded connection. The layers are also thinner, down to tenths of a millimeter. This uses less material, and our powder management enables us to achieve a high degree of powder utilization. The powder and hard material layers are applied directly one after the other. By applying the first layer, the brake disk is tempered, as it were, and we consistently achieve the best application quality for every brake disk without pores or cracks forming."

For more information contact:

CHIRON America, Inc.

10950 Withers Cove Park Drive

Charlotte, NC 28278


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