Automobile Brake Disc Coating Brake Disc Wear-resistant Coating

The core advantage of spraying wear-resistant coatings on automotive brake discs

(1) Enhance wear resistance to the extreme and extend service life

During the braking process, brake discs are constantly subjected to friction, wear and thermal shock. Traditional cast iron brake discs are prone to thinning due to wear and an increase in braking clearance. After applying the WC-10Co4Cr tungsten carbide-based coating, the 300μm thick coating formed by supersonic flame spraying technology can increase the surface hardness of the brake disc by three times and reduce the wear by 85% compared with traditional cast iron discs. The NiCrBSi flame-sprayed coating can also significantly reduce wear and tear, extend the service life of brake discs by 2 to 3 times compared to the original product, and greatly lower the replacement frequency and maintenance costs for car owners.

(2) Stabilize the coefficient of friction to ensure braking safety

Braking safety depends on the stable output of the coefficient of friction. Experimental data shows that the friction coefficient of traditional cast iron brake discs fluctuates within the range of 0.43 to 0.61, while WC-based coated brake discs can control the friction coefficient within the optimal range of 0.47 to 0.62, maintaining stability even under high-speed and high-temperature working conditions. For high-speed braking scenarios, brake discs coated with laser-melted cobalt-based alloy can withstand emergency braking at 400km/h. Even when the maximum surface temperature reaches 728.5℃, they still maintain an effective friction coefficient of 0.29-0.44, and the number of thermal fatigue cracks is significantly reduced, completely eliminating the "thermal fade" hazard of traditional brake discs during high-speed braking.

(3) Enhance heat resistance and corrosion resistance to adapt to complex environments

Brake discs are exposed to corrosive media such as rainwater and salt for a long time, and the sudden rise and fall in temperature during braking can easily cause oxidation and rust. The wear-resistant coating forms a physical barrier through a dense microstructure, effectively isolating moisture and oxygen erosion. Among them, the WC base coating contains hard phases such as WC and W₂C, which not only enhance wear resistance but also resist high-temperature oxidation. Cobalt-based alloy coatings can maintain structural stability even in high-temperature environments above 700℃, preventing coating peeling or performance degradation, and are suitable for various climatic conditions such as severe cold in the north and high humidity along the coast.

The exclusive service advantages of Zhengzhou Lijia Thermal Spraying

(1) Technical hard power: Leading the industry in equipment and technology

As a high-tech enterprise and a gazelle enterprise, Lijia holds 121 patent technologies (including 2 invention patents and 36 utility model patents), and its independently developed HVAF supersonic flame spraying system has reached international standards. This system uses propane and compressed air as fuel, and is equipped with multiple types of nozzles that are compatible with coating materials of different melting points. Combined with the D-3000 high-precision powder feeder (with measurement accuracy far exceeding that of traditional equipment) and the robotic arm automated production line, it can achieve precise control of coating thickness error within ±5μm, ensuring that the uniformity and bonding strength of the coating on each brake disc meet the standards. Its technical strength has been internationally recognized.

(2) Full-chain service: Seamless coverage from design to after-sales

Relying on nearly two decades of experience in thermal spraying, Lijia has established a full-process service system covering "coating customization - processing and production - testing and after-sales service". For automotive brake disc scenarios, customized coating solutions such as WC-based and NiCrBSi can be provided based on the vehicle type (family cars, commercial vehicles, new energy vehicles) and usage scenarios (urban commuting, mountain road off-roading). The production end is equipped with multiple standard spray booths and supporting facilities such as lathes and grinders, achieving an integrated precision processing after spraying. The inspection process employs professional equipment such as SEM/EDS microscopic analysis and X-ray diffraction to replicate international testing standards like SAE-J2430, ensuring the traceability of coating performance. The after-sales team can respond to fault handling within 24 hours. The layout of the Wuxi branch and the Shenzhen R&D center further realizes the coverage of the national service network.

(3) Cost and efficiency advantages: Compatible with batch and personalized demands

Lijia has increased its processing efficiency by 40% through an automated production line (including robotic arms, turntable fixtures, and dust removal systems). Meanwhile, its integrated "spraying + mechanical processing" capacity can reduce intermediate circulation links, shortening the single-piece processing cycle to within 24 hours. For bulk orders from automakers, large-scale production can be achieved by relying on the cluster advantages of the Zhengzhou Thermal Spraying Industrial Base. For the personalized demands of the maintenance market, the coating materials and thickness can be flexibly adjusted. As a local enterprise, the logistics cost is reduced by 20% to 30% compared with service providers from other places, taking into account both cost performance and delivery speed.

(4) Dual guarantee of qualifications and reputation

Lijia holds 10 qualification certificates and 6 administrative licenses, has passed the ISO system certification, and has participated in 26 national-level bidding projects (such as winning the bid for the spray system procurement of China State Shipbuilding Corporation). Its service cases are spread all over the country. After visiting many places such as Beijing, Shanghai, Guangzhou and Zhengzhou, enterprises like Xiamen and Xiangtan Shuncheng finally chose Lijia because of its "stable coating quality and prompt after-sales response". This advantage of combining technical reliability with service flexibility makes it the preferred partner for auto parts manufacturers and repair institutions.