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Optimizing Sol-Gel Coatings for Corrosion Protection of Braking Discs

Picture for Optimizing Sol-Gel Coatings for Corrosion Protection of Braking Discs
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As far as the automotive sector is concerned, braking discs (BDs) are objects usually made of Grey Cast-Iron (GCI), i.e. a material exhibiting overall good mechanical properties and castability, but poor corrosion resistance. In particular, looking at the standard working conditions of a disc brake system, several environmental factors can cause and enhance GCI corrosion phenomena, such as: i) atmospheric moisture; i) ionic species contained in aerosols (e.g., chlorides and sulfates); iii) air differential corrosion caused by discs surface soiling by mud or other materials; and iv) galvanic coupling between the rotor and the braking pads.

Product Number: 51323-18872-SG
Author: Nicola Nocera, Bozhena Tsyupa, Marco Bandiera, Mary Angel Abello, Pietro Della Bella, Alessandro Piglione, Andrea Bonfanti, Federico Bertasi
Publication Date: 2023
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This manuscript describes the development and optimization of sol-gel SiO2 -based Hybrid-Organic-Inorganic (HIO) coatings for application as corrosion protective layer on rotors employed in disc brake systems. The corrosion protection achieved with the coatings is optimized by tuning their water wettability, surface free energy (SFE), thickness and cross-linking degree, which strongly depend on sol chemical composition. Optimal film features are obtained modifying the silica network with organic components and accurately tailoring the deposition parameters. In particular, a Design of Experiment (DoE) approach is used to optimize the composition of the coatings and thereby their corrosion protection capability. Anti-corrosion properties of the coatings are assessed by means of the voltammetry probe: the corrosion potential and corrosion current, as obtained from Tafel curve fitting, are used as figures of merit. Their correlation with synthesis parameters such as silica concentration, inorganic/organic silane ratio and film thickness are widely discussed to determine the most relevant factors in the production of such coatings as protective layers for braking discs.

This manuscript describes the development and optimization of sol-gel SiO2 -based Hybrid-Organic-Inorganic (HIO) coatings for application as corrosion protective layer on rotors employed in disc brake systems. The corrosion protection achieved with the coatings is optimized by tuning their water wettability, surface free energy (SFE), thickness and cross-linking degree, which strongly depend on sol chemical composition. Optimal film features are obtained modifying the silica network with organic components and accurately tailoring the deposition parameters. In particular, a Design of Experiment (DoE) approach is used to optimize the composition of the coatings and thereby their corrosion protection capability. Anti-corrosion properties of the coatings are assessed by means of the voltammetry probe: the corrosion potential and corrosion current, as obtained from Tafel curve fitting, are used as figures of merit. Their correlation with synthesis parameters such as silica concentration, inorganic/organic silane ratio and film thickness are widely discussed to determine the most relevant factors in the production of such coatings as protective layers for braking discs.

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