Influence of corrosion on wear and brake particle emissions of alumina-coated and uncoated cast iron brake discs
Cai, Ran ; Nie, Xueyuan ; Lyu, Yezhe LU
and Wahlström, Jens
LU
(2025)
In Surface and Coatings Technology
516.
- Abstract
Hard alumina-based coatings can be applied to cast iron brake discs using a plasma electrolytic aluminating (PEA) process to enhance wear and corrosion resistance and reduce brake particle emissions. This work was first to study the influence of friction wear on corrosion property and then investigate the influence of corrosion on brake particle emissions from cast iron discs through comparison of alumina-coated and uncoated surfaces. During each of three corrosion-tribotest cycles, four discs were subjected to exposure to rainy-snowy conditions for 24 or 72 h before the undergoing tribological tests using a pin-on-disc tribotester combined with an airborne particle emission measurement system. The counterpart pins were machined from a... (More)
Hard alumina-based coatings can be applied to cast iron brake discs using a plasma electrolytic aluminating (PEA) process to enhance wear and corrosion resistance and reduce brake particle emissions. This work was first to study the influence of friction wear on corrosion property and then investigate the influence of corrosion on brake particle emissions from cast iron discs through comparison of alumina-coated and uncoated surfaces. During each of three corrosion-tribotest cycles, four discs were subjected to exposure to rainy-snowy conditions for 24 or 72 h before the undergoing tribological tests using a pin-on-disc tribotester combined with an airborne particle emission measurement system. The counterpart pins were machined from a commercially available low-steel (LS) brake pad. Data of particle concentration, size distribution, and total wear (disc and pad) were collected, while wear tracks and friction transferred layers were analyzed using scanning electron microscopy (SEM). The results showed that uncoated discs developed visible rust layers up to 10 or 30 μm thickness after 24- or 72-hour corrosion exposure respectively and the degree of corrosion increased with exposure time, while the alumina-coated discs exhibited no corrosion signs. The early stage of tribotests quickly removed the rust layers which caused sharp particle emission peaks for the uncoated discs. The PEA coatings led to 80 % less particle number concentration (PNC) and negligible disc weight loss while reducing pad weight loss by nearly 50 %. These findings demonstrate the potential of PEA coatings in reduction of wear and emissions under winter conditions.
(Less)
- author
- Cai, Ran
; Nie, Xueyuan
; Lyu, Yezhe
LU
and Wahlström, Jens
LU
- organization
- publishing date
- 2025-11-15
- type
- Contribution to journal
- publication status
- published
- subject
- keywords
- Brake disc, Coating, Corrosion, Particle emission, Tribology, Wear
- in
- Surface and Coatings Technology
- volume
- 516
- article number
- 132765
- pages
- 10 pages
- publisher
- Elsevier
- external identifiers
-
- scopus:105018304196
- ISSN
- 0257-8972
- DOI
- 10.1016/j.surfcoat.2025.132765
- language
- English
- LU publication?
- yes
- additional info
- Publisher Copyright: © 2025
- id
- 98880278-3538-4900-865f-7d2bedfbbb9a
- date added to LUP
- 2025-10-23 08:36:20
- date last changed
- 2025-10-30 14:59:44
@article{98880278-3538-4900-865f-7d2bedfbbb9a,
abstract = {{<p>Hard alumina-based coatings can be applied to cast iron brake discs using a plasma electrolytic aluminating (PEA) process to enhance wear and corrosion resistance and reduce brake particle emissions. This work was first to study the influence of friction wear on corrosion property and then investigate the influence of corrosion on brake particle emissions from cast iron discs through comparison of alumina-coated and uncoated surfaces. During each of three corrosion-tribotest cycles, four discs were subjected to exposure to rainy-snowy conditions for 24 or 72 h before the undergoing tribological tests using a pin-on-disc tribotester combined with an airborne particle emission measurement system. The counterpart pins were machined from a commercially available low-steel (LS) brake pad. Data of particle concentration, size distribution, and total wear (disc and pad) were collected, while wear tracks and friction transferred layers were analyzed using scanning electron microscopy (SEM). The results showed that uncoated discs developed visible rust layers up to 10 or 30 μm thickness after 24- or 72-hour corrosion exposure respectively and the degree of corrosion increased with exposure time, while the alumina-coated discs exhibited no corrosion signs. The early stage of tribotests quickly removed the rust layers which caused sharp particle emission peaks for the uncoated discs. The PEA coatings led to 80 % less particle number concentration (PNC) and negligible disc weight loss while reducing pad weight loss by nearly 50 %. These findings demonstrate the potential of PEA coatings in reduction of wear and emissions under winter conditions.</p>}},
author = {{Cai, Ran and Nie, Xueyuan and Lyu, Yezhe and Wahlström, Jens}},
issn = {{0257-8972}},
keywords = {{Brake disc; Coating; Corrosion; Particle emission; Tribology; Wear}},
language = {{eng}},
month = {{11}},
publisher = {{Elsevier}},
series = {{Surface and Coatings Technology}},
title = {{Influence of corrosion on wear and brake particle emissions of alumina-coated and uncoated cast iron brake discs}},
url = {{http://dx.doi.org/10.1016/j.surfcoat.2025.132765}},
doi = {{10.1016/j.surfcoat.2025.132765}},
volume = {{516}},
year = {{2025}},
}