Re: Material Properties of Thermally Sprayed Coatings

Posted by Gordon England on April 22, 2003 at 02:46:03:

In Reply to: Material Properties of Thermally Sprayed Coatings posted by Adam Karl on March 26, 2003 at 08:40:24:

: Hi all,

: I am looking into designing thermally sprayed aluminium brake rotors for a formula SAE car (small opened-wheel racing car, see link). I am considering an alumina oxide coating or a copper-stainless steel arc sprayed coating. I need the thermal and mechanical properties of these coatings to complete my study (which forms part of my University Thesis). Does anyone know where this type of data is available? I have contacted manufacturers but they are not willing to help.

: Thank you

Hi Adam

I think you will have problems obtaining good specific information on this subject at this time.
The following may give you some rough ideas:

Thermal conductivity
Plasma spray alumina 2 - 4 W/mK
Arc spray steel/copper 20 -50 W/mK

Tensile bond strength 25 - 50 Mpa

The above is very rough and ready as the properties will be be effected by the spray materials, process, substrate preparation and bond coats used.

Generally, thermal spray coatings appear suited to this application. The metallic coatings perform well for non-aggressive conditions but under aggressive racing conditions the aluminium melts underneath the coating causing failure. The thermal barrier properties of ceramic coatings can greatly retard this effect. Design for cooling of disc and matching of brake pad materials are also very important factors.

Regards Gordon

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