Ceramic protection plates brazed to aluminum brake discs

Abstract Aluminum alloys are light-weight and one of the most interesting material solutions to optimize the strength/weight ratio to reduce car weight; however they are also relatively soft and therefore cannot be used for intensive wear applications. We developed an aluminum alloy part combined with hard and wear-resistant Al2O3-based ceramic plates on the surface for demanding mechanical parts for automotive industry such as disc brakes. Tribological tests of various engineering ceramic materials were performed in order to find a ceramic material with a combination of coefficient, wear resistance and thermal energy dissipation for the car brakes. Al2O3-based ceramic showed promising properties, as well as being cost effective. Two different approaches to braze ceramic on aluminum were investigated. A two-step brazing process using Cu-Sn-Ti-Zr filler alloy and a single step ultrasonic active soldering with Sn-Ag-Ti filler alloy. Larger areas of aluminum could be covered with a segmented brake design in which many ceramic plates were joined surface. Comparable tribological properties to those of the bulk ceramic material were achieved.

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