{"id":3333,"date":"2025-09-18T08:10:41","date_gmt":"2025-09-18T13:10:41","guid":{"rendered":"https:\/\/www.emag.com\/blog\/en\/?p=3333"},"modified":"2025-09-18T08:10:41","modified_gmt":"2025-09-18T13:10:41","slug":"coordinating-laser-metal-deposition-and-grinding-for-coated-brake-discs","status":"publish","type":"post","link":"https:\/\/www.emag.com\/blog\/en\/coordinating-laser-metal-deposition-and-grinding-for-coated-brake-discs\/","title":{"rendered":"Why coordinating laser metal deposition and grinding is crucial for the coated brake disc quality"},"content":{"rendered":"

The design and development of coated brake discs are becoming increasingly important in the automotive industry. The main driver behind this shift is the need to reduce brake dust emissions, as mandated by international regulations like GTR 24 and the Euro 7 standard. These regulations set strict limits on particulate emissions (PM10): capping them at 7 mg\/km for passenger cars and as low as 3 mg\/km for electric vehicles. These standards will be enforced across the European Union starting in November 2027, with a similar regulation expected to take effect in China between 2028 and 2030 under the National 7 standard. <\/strong><\/p>\n

To meet these emission targets, manufacturers are increasingly turning to coated brake discs, with Laser Metal Deposition (LMD) emerging as a promising technology. However, the precision required to manufacture these complex components presents significant challenges. The key to achieving high-quality, cost-effective brake discs lies in the coordination between the laser coating process and the subsequent grinding process.\u00a0<\/strong><\/p>\n

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Basics: The process steps for <\/span>hard coating <\/span>brake discs<\/span><\/span>\u00a0<\/span><\/h3>\n

The production of coated brake discs involves several essential process steps<\/span><\/span>:<\/span>\u00a0<\/span><\/p>\n

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  1. Turning<\/span><\/span>: <\/strong><\/span>The blanks are first precision pre-turned.<\/span><\/span>\u00a0<\/span><\/span><\/li>\n
  2. Laser coating<\/span><\/span>:<\/strong> Depending on the requirements, a single-layer or multi-layer coating is applied.<\/span><\/span><\/span><\/li>\n
  3. Grinding:<\/strong> The coated surface is ground to meet the functional requirements<\/span><\/span>.<\/span>\u00a0<\/span><\/li>\n<\/ol>\n

    For conventional brake discs, finish turning is<\/span> commonly<\/span> used in Europe, while grinding processes are more <\/span>prevalent <\/span>in Asia. However, <\/span>for <\/span>the hard coating of brake discs<\/span>,\u00a0<\/span>grinding <\/span>is necessary, <\/span>as the surface roughness after coating is <\/span>typically <\/span>too high for direct use<\/span><\/span>.<\/span>\u00a0<\/span><\/p>\n

    \"The

    Four brake discs in the state after turning, coating of adhesive layer, coating of friction layer and grinding – side by side to illustrate the process sequence.<\/p><\/div>\n

     <\/p>\n

    Laser coating process: the foundation for high-quality brake discs<\/span><\/b><\/p>\n

    Laser metal deposition of brake discs is performed using advanced LMD machines, such as the EMAG ELC 450 LMD<\/strong><\/a>. <\/span>The coating typically consists of two layers:<\/span>\u00a0<\/span><\/p>\n

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    1. Adhesive layer<\/span><\/span>:<\/strong> A <\/span>stainless steel<\/span> matrix <\/span>layer, <\/span>approximately <\/span>100-150<\/span> micrometers<\/span> thick<\/span><\/span>\u00a0<\/span><\/span><\/li>\n
    2. Friction layer<\/span><\/b>: A mixture of titanium carbides and stainless steel matrix approximately 250 micrometers thick<\/span>\u00a0<\/span><\/li>\n<\/ol>\n

      \u00a0<\/span>The quality of this coating depends on<\/span>\u00a0<\/span><\/p>\n