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What are the methods to improve the wear and corrosion resistance of grey cast iron brake rotors?

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To improve the wear and corrosion resistance of gray cast iron brake rotors, several methods have been studied. One approach is to laser clad the surface of the brake discs with harder and corrosion-resistant materials such as Inconel 718 (IN718) metallic powder . This process forms a uniform and adherent interface between the substrate and the deposited material, resulting in a compact bonding of the two materials. Laser cladding with IN718 significantly increases the hardness of the deposited material and improves the friction coefficient compared to the substrate material. It also reduces the depth of the wear track and enhances the corrosion resistance of the brake discs . Another method involves the use of a new Al2O3-Ni composite coating prepared through plasma electrolytic aluminating (PEA) followed by electroless nickel plating (ENP) processes. This coating has shown promising results in improving brake rotor wear and corrosion resistance for electric vehicles (EVs) .

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Open access•Posted Content•DOI Tribology and corrosion behavior of Gray Cast Iron brake discs coated with Inconel 718 by Direct Energy Deposition 14 Mar 2022	The paper discusses the use of laser cladding with Inconel 718 metallic powder by Direct Energy Deposition (DED) method to improve the wear and corrosion resistance of grey cast iron brake discs.
Journal Article•DOI Investigation of Al2O3-Ni Coated Cast Iron Brake Rotors Under Modified Brake Dynamometer Test Standards Ran Cai, Jiayi Sun, Jingzeng Zhang, Jimi Tjong, Sean Foots, Mark Lavelle, Xueyuan Nie - Show less +6 more 29 Mar 2022-SAE International journal of advances and current practices in mobility	The paper suggests using a new Al2O3-Ni composite coating on cast iron brake rotors to improve wear and corrosion resistance.
Open access•Journal Article•DOI Tribology and corrosion behavior of gray cast iron brake discs coated with Inconel 718 by direct energy deposition Diana Chioibasu, Sabin Mihai, Cosmin Mihai Cotrut, Ionelia Voiculescu, Andrei C. Popescu - Show less +4 more 13 Jul 2022-The International Journal of Advanced Manufacturing Technology 3 Citations	The paper discusses the use of laser cladding with Inconel 718 to improve the wear and corrosion resistance of gray cast iron brake discs.
Open access•Journal Article•DOI Corrosion Stiction in Automotive Braking Systems Michele Motta, Lorenzo Fedrizzi, Francesco Andreatta - Show less +2 more 01 May 2023-Materials	The paper does not specifically mention methods to improve the wear and corrosion resistance of grey cast iron brake rotors.

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