Date of Award

9-25-2024

Publication Type

Thesis

Degree Name

M.Sc.

Department

Mechanical, Automotive, and Materials Engineering

Supervisor

Xueyuan Nie

Creative Commons License

Creative Commons Attribution 4.0 International License
This work is licensed under a Creative Commons Attribution 4.0 International License.

Abstract

Many developments in new brake pad formulation and brake rotor coating are taking place with the aim of helping car manufacturers become pollution-free and emissions-free. Plasma Electrolytic Oxidation process is a relatively new approach to produce an alumina ceramic coating on cast iron brake rotors (called PEA-coated rotors) with intention to reduce corrosion, emissions and noise. In this study, the PEA-coated rotors were installed into passenger vehicles which currently uses FNC-treated brake rotors in the market (FNC: ferrite nitrocarbursing). The test vehicles were fitted with a PEA brake rotor on the left brake corner and a FNC brake rotor or another PEA rotor on the right brake corner coupling with the same kind of OEM brake pads. After hundreds of times of braking in daytimes and standing in dry and raining nights, the rotor surface conditions and corrosion appearance were investigated using optical and scanning electron microscopies. The corrosion and material transferring were determined by measuring thickness and weight changes before and after the vehicle test. The degrees of wear, materials transfer, and corrosion were found different on the different rotors. The PEA-coated rotor had a better corrosion and wear resistance than the FNC-treated rotor, leading to possible further brake emission reduction. However, there is a need to find a better compatible brake pad to match the alumina-coated rotor.

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