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  • 1.
    Aranke, Omkar
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Algenaid, Wael
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Awe, Samuel
    R and D Department, Automotive Components Floby AB, Floby, 52151, Sweden.
    Joshi, Shrikant V.
    University West, Department of Engineering Science, Research Enviroment Production Technology West.
    Coatings for automotive gray cast iron brake discs: A review2019In: Coatings, ISSN 2079-6412, Vol. 9, no 9, article id 552Article in journal (Refereed)
    Abstract [en]

    Gray cast iron (GCI) is a popular automotive brake disc material by virtue of its high melting point as well as excellent heat storage and damping capability. GCI is also attractive because of its good castability and machinability, combined with its cost-effectiveness. Although several lightweight alloys have been explored as alternatives in an attempt to achieve weight reduction, their widespread use has been limited by low melting point and high inherent costs. Therefore, GCI is still the preferred material for brake discs due to its robust performance. However, poor corrosion resistance and excessive wear of brake disc material during service continue to be areas of concern, with the latter leading to brake emissions in the form of dust and particulate matter that have adverse effects on human health. With the exhaust emission norms becoming increasingly stringent, it is important to address the problem of brake disc wear without compromising the braking performance of the material. Surface treatment of GCI brake discs in the form of a suitable coating represents a promising solution to this problem. This paper reviews the different coating technologies and materials that have been traditionally used and examines the prospects of some emergent thermal spray technologies, along with the industrial implications of adopting them for brake disc applications. © 2019 by the authors.

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  • 2.
    Aranke, Omkar
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Gupta, Mohit Kumar
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Markocsan, Nicolaie
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Li, Xin-Hai
    Siemens Industrial Turbomachinery AB, Finspång, Sweden.
    Kjellman, Björn
    GKN Aerospace Sweden AB, Trollhättan, Sweden.
    Microstructural Evolution and Sintering of Suspension Plasma-Sprayed Columnar Thermal Barrier Coatings2019In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 28, no 1-2, p. 198-211Article in journal (Refereed)
    Abstract [en]

    Suspension plasma spray (SPS) is capable of producing coatings with porous columnar structure, and it is also a much cheaper process compared to the conventionally used electron beam physical vapor deposition (EB-PVD). Although TBCs with a columnar microstructure that are fabricated using SPS have typically lower thermal conductivity than EB-PVD, they are used sparingly in the aerospace industry due to their lower fracture toughness and limited lifetime expectancy. Lifetime of TBCs is highly influenced by the topcoat microstructure. The objective of this work was to study the TBCs produced using axial SPS with different process parameters. Influence of the microstructure on lifetime of the coatings was of particular interest, and it was determined by thermal cyclic fatigue testing. The effect of sintering on microstructure of the coatings exposed to high temperatures was also investigated. Porosity measurements were taken using image analysis technique, and thermal conductivity of the coatings was determined by laser flash analysis. The results show that axial SPS is a promising method of producing TBCs having various microstructures with good lifetime. Changes in microstructure of topcoat due to sintering were seen evidently in porous coatings, whereas dense topcoats showed good resistance against sintering.

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    fulltext
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