1 Introduction
2 Experimental Setup
2.1 Cladding Process of Rotor
2.2 Tribological Experiment
2.2.1 Pre-tests
2.2.2 Pin-on-Disc Tests
Element (wt%) | Surface condition | ||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|
C | Cr | Ni | Mo | Si | Mn | Fe | Cu | O | Other | ||
Laser cladding overlay, Rockit 401 | 0.13 | 18 | 2.5 | 0.5 | – | – | Bal | – | – | – | Ra = 0.25 μm |
GCI rotor | 3.8 | – | – | – | 1.8 | 0.65 | Bal | – | – | – | Ra = 0.31 μm |
Brake pad-pin | N/A | 1.5 | – | – | 3.7 | - | 13.1 | 12.1 | 30.9 | Bal | Scorched |
2.3 Life Cycle Assessment
3 Results
3.1 Tribological and Emission Issues
Disc type | Pin loss [mg] | Disc loss [mg] | CoF | PNC (1/cm3) |
---|---|---|---|---|
Cast iron | 62 ± 2 | 58 ± 8 | 0.52 ± 0.01 | 130 ± 54 |
Laser-cladded | 83 ± 6 | 105 ± 8 | 0.72 ± 0.01 | 299 ± 45 |
Cast iron | Laser cladding | |
---|---|---|
O | 9.8 \(\pm\) 0.1 | 9.8 \(\pm\) 0.5 |
Mg | 2.7 \(\pm\) 0.3 | 2.1 \(\pm\) 0.1 |
Al | 2.6 \(\pm\) 0.4 | 2.0 \(\pm\) 0.2 |
Si | 2.8 \(\pm\) 0.8 | 1.3 \(\pm\) 0.1 |
S | 2.6 \(\pm\) 0.2 | 2.1 \(\pm\) 0.1 |
Ca | 1.7 \(\pm\) 0.3 | 1.4 \(\pm\) 0.1 |
Cr | 1.2 \(\pm\) 0.1 | 9.0 \(\pm\) 1.8 |
Fe | 50.9 \(\pm\) 1.5 | 36.2 \(\pm\) 0.8 |
Ni | – | 0.8 \(\pm\) 0.3 |
Cu | 13.3 \(\pm\) 0.1 | 26.0 \(\pm\) 3.2 |
Zn | 7.3 \(\pm\) 0.2 | 5.3 \(\pm\) 0.5 |
Sn | 4.6 \(\pm\) 0.6 | 3.9 \(\pm\) 0.1 |
GCI | Laser-cladded | |||||
---|---|---|---|---|---|---|
PM10 | PM2.5 | PM1 | PM10 | PM2.5 | PM1 | |
O | 7.3 ± 1.6 | 12.6 ± 0.9 | 8.5 ± 2.2 | 6.0 ± 2.2 | 5.1 ± 2.9 | 10.6 ± 3.0 |
Mg | 2.5 ± 0.2 | 3.2 ± 0.5 | 2.3 ± 0.5 | 1.5 ± 0.6 | 1.2 ± 0.5 | 2.4 ± 0.6 |
Al | 2.6 ± 0.4 | 3.5 \(\pm\) 0.1 | 3.1 \(\pm\) 0.3 | 2.3 \(\pm\) 0.4 | 2.2 \(\pm\) 0.0 | 2–3 \(\pm\) 0.6 |
Si | 2.4 \(\pm\) 0.3 | 3.5 \(\pm\) 0.5 | 3.4 \(\pm\) 0.3 | 1.8 ± 0.5 | 1.2 ± 0.2 | 2.0 ± 0.4 |
S | 2.4 \(\pm\) 0.1 | 2.5 \(\pm\) 0.3 | 2.5 \(\pm\) 0.1 | 1.9 ± 0.6 | 2.2 \(\pm\) 0.7 | 2.0 0.2 |
K | 0.1 \(\pm\) 0.0 | 0.2 \(\pm\) 0.0 | 0.2 \(\pm\) 0.1 | – | – | – |
Ca | 1.4 \(\pm\) 0.1 | 1.7 \(\pm\) 0.2 | 2.0 \(\pm\) 0.2 | 1.5 \(\pm\) 0.4 | 1.3 \(\pm\) 0.1 | 1.2 \(\pm\) 0.1 |
Cr | 0.9 \(\pm\) 0.1 | 0.9 \(\pm\) 0.1 | 1.0 \(\pm\) 0.2 | 13.4 \(\pm\) 2.6 | 11.8 \(\pm\) 0.2 | 10.9 \(\pm\) 0.4 |
Mn | 0.2 \(\pm\) 0.1 | – | – | – | – | – |
Fe | 63.7 \(\pm\) 1.5 | 56.2 \(\pm\) 1.6 | 61.2 \(\pm\) 1.9 | 57.0 ± 1.7 | 59.4 ± 3.1 | 54.0 ± 1.9 |
Ni | – | – | – | 0.4 \(\pm\) 0.1 | 1.2 \(\pm\) 0.3 | 1.4 \(\pm\) 0.1 |
Cu | 6.4 \(\pm\) 0.9 | 6.4 \(\pm\) 0.2 | 6.6 \(\pm\) 0.3 | 6.1 \(\pm\) 1.2 | 5.5 \(\pm\) 0.1 | 5.1 \(\pm\) 0.3 |
Zn | 5.7 0.3 | 5.6 \(\pm\) 0.5 | 5.4 \(\pm\) 0.1 | 4.9 \(\pm\) 0.3 | 5.0 ± 0.2 | 5.2 ± 0.3 |
Sn | 4.0 \(\pm\) 0.3 | 3.8 \(\pm\) 0.1 | 3.9 \(\pm\) 0.2 | 3.4 \(\pm\) 0.3 | 3.7 \(\pm\) 0.6 | 2.8 \(\pm\) 0.4 |
3.2 Life Cycle Assessment of the Proposed Reuse Approach
CO2 footprint (kg) | Total | End-of-life potential | ||||
---|---|---|---|---|---|---|
Material | Manufacturing | Transport | Disposal | |||
Standard disc | 20.8 | 20.3 | 2.3 | 0.4 | 43.8 | − 8.6 |
Remelted disc | 10.6 | 20.3 | 2.4 | 0.4 | 33.7 | − 8.6 |
Laser-cladded disc | 9.4 | 7.4 | 1.9 | 0.4 | 19.1 | − 17.3 |
Energy (MJ) | Total | End-of-life potential | ||||
---|---|---|---|---|---|---|
Material | Manufacturing | Transport | Disposal | |||
Standard disc | 273.1 | 275.2 | 34.1 | 5.0 | 587.4 | − 112.6 |
Remelted disc | 138.8 | 275.2 | 34.1 | 5.0 | 453.1 | − 112.6 |
Laser-cladded disc | 179.7 | 16.3 | 27.2 | 5.6 | 228.2 | − 138.3 |