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High-speed laser metal deposition on brake disks

Automotive TruLaser Cell Additive manufacturing

Even low concentrations of fine dust can be harmful to health. Fine dust is caused by wear and tear on brakes, tires, clutches and road surfaces. More than half of the fine dust from road traffic can be attributed to the braking process, or more precisely the wear of brake disks, brake shoes and tires. In the future, high-speed laser  metal  deposition will be used to coat Euro7-compliant, low-wear brake disks. Brake disks coated in this way emit far less fine dust than conventional brake disks.  The process not only ensures less fine dust, but also less wear.  The brake disk is usually coated with two layers. The first layer primarily serves as an anticorrosive agent and is usually comprised of stainless steel and nickel-free steel. The second layer consists of a mixture of hard carbides such as titanium carbide or tungsten carbide and a steel.  Electric vehicles can also benefit from this coating technology in the future, as the energy recovery process during braking means that disk brakes are rarely used. As a result, the brake disk can oxidize or even corrode, which leads to a loss of braking performance and, in extreme cases, may require premature replacement. High-speed laser metal deposition of oxidation- and corrosion-resistant materials on electric vehicle brake disks can counteract this risk. 


Protection against wear and corrosion
High productivity
Metallurgical bonding of substrate and sheathing

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Facts & figures for an example part

Material: Multi-layer recoating system made of ceramic and metal 

Part dimensions: Demo parts H 300 mm, Ø 120 mm; 

Typical brake disk dimensions: approx. Ø 250-450 mm 

Surface rate: up to 1500 cm²/min; depending on raw material and layer thickness 

Typical layer thickness: 100-300 µm 

High-speed laser metal deposition is cost-effective, can be used in series production and therefore has the potential to become the new standard in the manufacture of brake disks.

Richard Bannmüller
President and Chairman of the Managing Board of TRUMPF Laser- und Systemtechnik

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TruLaser Cell 3000
TruLaser Cell 3000

The 3D laser machine TruLaser Cell 3000 from TRUMPF can be used for two- and three-dimensional cutting and welding, as well as for additive manufacturing or laser metal deposition (LMD). Highspeed laser metal deposition for rotationally symmetrical components is possible as well. From prototypes to large-scale series production, this multi-talented machine displays its superiority across the board.

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