Simulation of thermal and mechanical performance of laser cladded disc brake rotors

Nicholas Athanassiou* (Corresponding Author), Ulf Olofsson, Jens Wahlström, Senad Dizdar

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

8 Citations (Scopus)
5 Downloads (Pure)


Disc brakes wear during braking events and release airborne particulates. These particle emissions are currently one of the highest contributors to non-exhaust particle emissions and introduce health hazards as well as environmental contamination. To reduce this problem, wear and corrosion-resistant disc coatings have been implemented on grey cast iron brake disc rotors by using various deposition techniques such as thermal spraying and overlay welding. High thermal gradients during braking introduce risks of flaking off and cracking of thermally sprayed coatings with adhesive bonding to the substrate. Overlay welding by laser cladding offers metallurgical bonding of the coating to the substrate and other benefits that motivate laser cladding as a candidate for the coating of the grey cast iron brake discs. This study aims to investigate the effect of laser cladding on the thermal and thermo-structural performance of the coated grey cast iron brake discs. Therefore, thermal and thermo-stress analysis with COMSOL Multiphysics 5.6 software is performed on braking events of grey cast iron brake discs as non-coated – reference and laser cladding coated with stainless steel welding consumables. The Results demonstrated that surface temperatures were more localised, overall higher in the laser cladded coating with over three times the stresses attained of reference grey cast iron discs. The output of the simulations has been compared by tests found in the literature. Laser cladding presented higher reliability and braking performance, nonetheless requiring the evaluation of its thermal impact on other system components.
Original languageEnglish
Pages (from-to)3-14
Number of pages12
JournalProceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology
Issue number1
Early online date13 Apr 2021
Publication statusPublished - 1 Jan 2022
Externally publishedYes

Bibliographical note

Open access via Sage agreement

The authors received no financial support for the research, authorship and/or publication of this article.

The authors are grateful for the contributions provided by Fabrizio Girolimetti on simulation development.


  • laser cladding
  • coating
  • grey cast iron
  • disc brakes
  • friction
  • thermal stress
  • thermal performance


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