Coating solutions for enhancing automotive brake disc durability against corrosion and wear—a review

Abstract

Abstract The automotive industry’s relentless pursuit of improved safety, performance, and durability has spurred a continuous search for innovative solutions for crucial components like brake discs. These components endure extreme thermal and mechanical stresses, making them highly susceptible to corrosion and wear. Inadequate corrosion resistance and excessive wear of brake disc material during service remain significant concerns, with the latter resulting in brake emissions in the form of dust and particulate matter that pose health risks to humans. As exhaust emission standards grow more stringent, it becomes imperative to address brake disc wear issues while maintaining material braking performance. This paper extensively examines recent brake disc coating advancements specifically designed to combat corrosion and wear challenges. It explores how these protective coatings interact with the broader automotive ecosystem, highlighting their pivotal role in ensuring safer, more resilient, and environmentally responsible vehicles. This paper also evaluates traditional coating technologies and materials alongside emerging alternatives for brake disc applications.