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Spearheading Surface Engineering Innovation for Brake Discs at Our Laser Center of Competence

Despite the increasing number of vehicles worldwide, the past two decades have seen significant progress in reducing fine-dust emissions from exhaust systems. Now, car makers are focusing on another critical component: brake discs, which account for 30% of fine dust emissions.

The Laser Cladding process of brake discs in full swing

​​​​​Brake discs can corrode easily, decreasing safety and operating comfort, particularly in electric vehicles. Additionally, fine particles emitted from friction brake systems can be detrimental to health.

Metco Joining & Cladding has responded to this industry challenge with an innovative coating solution. At the Laser Center of Competence in Wohlen, Switzerland, Dr. Hossein Najafi (Ph.D., MBA) and his team have developed a sustainable process that reduces emissions, improves performance, and extends the lifespan of brake discs.

The DiscCover™ Beam coating application uses high-speed laser cladding in combination with dedicated MetcoBrake™ powders to drastically reduce fine dust from vehicle braking, meeting the stringent requirements of the EURO 7 norm.

 

A look behind the scenes in the Laser Center of Competence, where the DiscCover™ Beam coating application was developed

At the Laser Center of Competence, Dr. Najafi’s team collaborates closely with customers to innovate laser technologies. Developments align with three primary technology trends:

  • high-speed deposition,
  • high-power deposition, and
  • the construction of 3D structures.

Central to this success is the 7-axis 3D Laser Center Gantry. This highly precise machine allows for the construction of intricate structures while controlling the temperature throughout the entire process.

As a significant highlight, based on our growth over the past several years, 2024 will see an expansion with the addition of two more machines recently purchased from Karl H. Arnold Maschinenfabrik GmbH & Co.KG. These state-of-the-art machines will enhance our capabilities, enabling faster production times and higher precision in our manufacturing processes, further strengthening customer support.

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