According to the Federal Environment Agency, the largest proportion of fine dust in traffic (approx. 60%) comes from abrasion of brakes, tires and the road. Technical solutions to reduce environmental pollution are still being tested or are not available. Expensive ceramic techniques are used for more wear-resistant tires and brake pads due to the lack of cheap alternatives. But the situation with the brake discs looks much more problematic, because there is no alternative to its manufacturing. There is no economical and above all environmentally friendly replacement. In particular due to the high loads in operation, they are one of the most stressed components on the car. Cast iron with embedded graphite is predominantly used here, but the price-performance ratio has so far justified the use of this material - despite the undisputed disadvantages.
However, this inexpensive material leads to high fine dust emissions during operation and therefore represents an immense environmental burden. The widespread coating processes such as electroplating or thermal spraying proved unsuitable as they cannot effectively protect the brake discs.
The special process control in the EHLA enables the production of low-wear brake discs:
This type of process control enables quick and economical coating of wear and corrosion protection layers for the first time. This leads to a drastic reduction in the environmental impact of fine dust:
In collaboration with the Fraunhofer Institute for Laser Technology ILT, HD has developed a new powder nozzle that can be used as a Plug-and-Play Solution for Series Production. The new principle provides for a monolithic structure of the powder tip module, consisting of an inner and an outer cone. This module can be preassembled using appropriate shape and position tolerances and replaced without the need for manual adjustment. Both the gap size and the wear resistance of the powder nozzle can be adjusted according to customer requirements. The conversion on site takes place in a very short time (1-2 minutes) without loss of quality.
HIGHNO - Powder Nozzle
HIGHNO - monolithic nozzle tip module
Report on the new powder nozzle "High Quality Powder Nozzle (HighNo)" in the article "Setting Sights on a 3D Process" in the magazine PhotonicsViews 5/2019 October / November
The EHLA process is a patented and award-winning process from the Fraunhofer-Institute for Laser Technology in Aachen. This is a revolutionary approach for the production of corrosion and wear resistant layers. This process is a further development of conventional laser cladding (LC), in which the innovation of the process method is defined by
Compared to conventional LC, higher process speeds and consequently higher coating rates are possible. Coatings can now be produced faster and more economically, while maintaining the decisive quality features of conventional LC (including metallurgically bonded layers without pores and cracks). The following pictures show the technological and economic advantages of the EHLA-process, which finally enable the process to be used in a large-scale production.
PDF: Coating hydraulic cylinders by EHLA © Fraunhofer ILT
PDF: Certified coatings with the EHLA process© Fraunhofer ILT
PDF: Powder Nozzle for EHLA Process© Fraunhofer ILT
The team from the Fraunhofer-Institute for Laser Technology has received several awards for its work in developing an alternative to chrome plating:
Laser material deposition or also known as cladding is one of the generative manufacturing processes. Here, a filler material in powder form is injected through a powder nozzle into the molten bath generated by the laser beam on the component surface and melted there. By moving the laser beam or the coating optics relative to the component and overlapping individual tracks, a layer is created on the component. The maximum process speeds achieved here are around 15-20 m / min. The main process features are:
PDF: Laser Technology for Repair and Functionalization© Fraunhofer ILT
Beam Shaping System
The company was founded in 2005 and is based at the Fraunhofer Institute for Laser Technology ILT in Aachen (Germany).
The main focus of the company is the development of special optics and tools for laser technology. In cooperation with the Fraunhofer ILT, powder nozzles for laser cladding in particular are developed and distributed.
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