The innovative brake disc coating technology that fulfils all technical requirements for the Euro 7 standard.
Even though the start of the Euro 7 standard with particulate emission limits for PM10 has not yet been finalized, Impact Innovations has already developed a solution with Impact Hybrid Brake Disc Coating® that not only complies with the 7 mg/km limit, but is also expected to comply with the 3 mg/km limit. At the same time, Impact Hybrid BDC® resists even the toughest cracking in combined corrosion tests without any delamination.
The Solution
With Impact Hybrid BDC®, Impact Innovations combines two technology worlds in two brake disc coating layers: The strong metallurgical bonding of a laser-cladded intermediate layer with the crack and corrosion-resistant cold-spray top layer.
The laser-cladded intermediate layer requires no surface preparation to achieve the highest metallurgical adhesion strength to the grey cast iron of the brake disc. The thin intermediate layer has only limited thermal impact on the disc, so that significant thermal distortion of the disc can be avoided. At the same time, the surface of the intermediate layer builds a perfect structure for applying a cold-spray top layer with similarly high adhesion strength without any further surface preparation.
The high kinetic energy at the impact of the applied cold-spray top layer reduces the tensions of the applied intermediate layer. In addition, with the compressed strength of the cold-spray top layer, a high-performance coating is built that leads to the highest crack resistance even under the harshest test conditions.
The Results
The Impact Hybrid Brake Disc Coating® technology (registered for patent) prevents any severe cracking even at the highest brake forces and under corrosive environments. This way, corrosion in the interface to the gray cast iron disc and thus delamination can be eliminated.
Low-cost standard powders can be used for the intermediate layer. The titanium-based matrix material of the top layer guarantees the highest resistance against corrosion and cracks. Even up to 720 hours of salt spray test are passed without any corrosion.
The wide choice of suitable carbide materials in the top layers allows significant cost reductions by applying even low-cost carbides like silicon-carbide.
The Results
The Impact Hybrid Brake Disc Coating® technology (registered for patent) prevents any severe cracking even at the highest brake forces and under corrosive environments. This way, corrosion in the interface to the gray cast iron disc and thus delamination can be eliminated.
Low-cost standard powders can be used for the intermediate layer. The titanium-based matrix material of the top layer guarantees the highest resistance against corrosion and cracks. Even up to 720 hours of salt spray test are passed without any corrosion.
Together with the latest special developments of leading brake pad suppliers, particle emissions can be drastically reduced, so that even the lowest emission limits below 3 mg/km can potentially be fulfilled. At the same time, these specially designed brake pads deliver very constant performance and desired friction values.