Applicability investigation of alumina-titania based plasma spray coating on cast iron brake discs for battery electric vehicles

Automobile brake disc are subjected to cyclic thermal, mechanical and corrosive effects. In general, gray cast iron grades are preferred as disc brake materials. Lamellar cast iron disc brakes have a limited lifetime and are replaced periodically during the maintenance-service process. With the growing interest in the number of Battery Electric Vehicles (BEV), there is a need for disc brake with longer service life on discs. Therefore, in the automotive sector, in line with increasing competition and user demands, there is an interest in new coating types and materials with corrosion free properties, a longer service life and high brake performance. Wear and corrosion resistant plasma spray coatings are the key to increasing the service life and braking performance of cast iron discs. In this study, the discs (GG20) are coated with Alumina- Titania based ceramic material by atmospheric plasma spray method. The ceramic coated disc brakes were installed on the road driving test vehicle and disc brake thickness reduction were measured periodically according to wear test plan throughout 20.000 km. The test results show that the ceramic coating provides 18 times more wear resistance compared to uncoated disc brake. In addition, coated disc brakes exhibited superior performance in corrosion tests. As a result of the investigations carried out on disc brakes, it is understood that plasma spray ceramic coatings can be used alternatively in brake disc systems.