Reliable brake solutions withstand the elements – ATEK Drive Solutions for your marine application.
Which materials are best suited for corrosion-resistant brake units in marine applications?
For marine applications, high-alloy stainless steels such as 1.4404 (316L) or duplex steels (e.g. 1.4462) are ideal. Duplex steels provide special protection against pitting corrosion with a PREN value over 32. ATEK relies on these materials to maximize the longevity of the brake units.
How does ATEK ensure protection against internal corrosion in its marine brake units?
ATEK uses redundant sealing systems with high-quality materials such as FKM (Viton®), which are temperature resistant up to 200°C. Designs with double sealing lips and grease chambers effectively protect internal components from invading saltwater.
What role do coatings play in corrosion-resistant brake units?
Coatings are an important part of the protection concept. ATEK relies on robust multi-layer coating systems, often a combination of zinc-rich epoxy primer and polyurethane topcoat. These systems can achieve protection durations of over 15 years according to ISO 12944 (Category C5-M) .
How are corrosion-resistant brake units for marine applications tested and certified?
Suitability is demonstrated through stringent tests , including salt spray tests (e.g. ASTM B117 for over 1000 hours), immersion tests, and dynamic load cycles under simulated marine conditions. Certifications by recognized classification societies such as DNV, ABS, or Lloyd’s Register confirm the quality and conformity.
Can brake units from ATEK be tailored to specific marine requirements?
Yes, ATEK specializes in customized special solutions. Thanks to our modular system design and our expertise in gear, brake, and motor construction, we can adapt brake units precisely to the respective requirements and environmental conditions.
What are the advantages of a modular design in marine brake units?
A modular design, as offered by ATEK, enables easy and quick replacement of components such as brake calipers. This can reduce maintenance time by up to 60% , which is particularly advantageous at sea and lowers operating costs., was besonders auf See von großem Vorteil ist und die Betriebskosten senkt.
How is biofouling minimized in ATEK marine brake units?
ATEK considers the risk of biofouling in the design. Through smooth surface designs and the possibility of using anti-fouling coatings or corrosion and biofouling resistant materials like copper-nickel alloys for components, the growth of marine organisms can be reduced by over 80% .
Does ATEK also offer complete drive solutions for marine applications?
Yes, as a system provider , ATEK covers the entire industrial drive chain. We combine our experience in brake and gear construction with expertise in servo motor manufacturing to deliver comprehensive and corrosion-resistant drive solutions for the specific requirements of the marine industry.
For maximum lifespan and reliability of brake units in marine environments, the selection of specific materials such as duplex stainless steels (PREN > 32) und multi-layer coating systems (protection duration >15 years according to ISO 12944 C5-M) is crucial to effectively resist corrosion.
Intelligent design features such as modular designs can reduce maintenance times by up to 60%, while redundant sealing systems and anti-fouling measures significantly increase the operational safety and efficiency von of corrosion-resistant brake units for marine applications. Comprehensive testing according to standards such as
Umfassende Tests nach Standards wie ASTM B117 (>1000 hours of salt spray) and certifications by classification societies (DNV, ABS) are essential to validate and ensure the suitability and long-term performance von of corrosion-resistant brake units under real marine conditions.Discover how ATEK Drive Solutions ensures the safety and longevity of your facilities in marine environments with innovative, corrosion-resistant brake units. Learn more about material selection, design optimization, and customized solutions.
The harsh conditions at sea pose the highest demands on drive technology. Corrosion is a constant threat. ATEK Drive Solutions offers specifically developed, corrosion-resistant brake units for marine applications that function reliably even under extreme conditions. Contact us for a personalized consultation at /contact.
Do you need a customized, corrosion-resistant brake solution for your marine application?
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Understand: why standard brakes fail at sea and require special solutions.
Standard brakes often fail in marine use due to the combination of saltwater and mechanical stress. Unprotected steel brakes can show significant corrosion damage after only six months. A specialized industrial brake must be designed from the outset for these conditions to avoid failures. ATEK analyzes specific environmental conditions for optimal results, especially in developing a corrosion-resistant brake unit for marine applications..
Marine-capable brakes require more than protective coatings: careful material selection, such as stainless steel 316L, and moisture-resistant constructions are needed. These factors, combined with rigorous testing, result in durable ship shaft brake systems – effective corrosion-resistant brake units for marine applications – which remain reliable even after five years of operation.Mastering: How saltwater, extreme weather, and dynamics challenge marine brakes.
Saltwater is the main enemy of metallic components at sea. Even the smallest coating defects can lead to corrosion within weeks, reducing the braking force of an anchor winch by up to 30%. A strategy against galvanic and crevice corrosion is essential for every stainless steel brake disc in shipping and thus for the entire corrosion-resistant brake unit for marine applications is essential.
Extreme temperature fluctuations, from -40°C to over +50°C, require special materials and thermally stable components. These must maintain their function over a temperature range of over 90 Kelvin, as tests on brakes for marine use, often specialized corrosion-resistant brake units for marine applications, show.
Ships are subject to constant vibrations and shocks. Offshore supply vessels experience accelerations of up to 5g in rough seas. FEA in the design phase identifies weaknesses and designs brake system structures for peak loads, which enhances the operational safety of of corrosion-resistant brake units for marine applications. .Designing: With which materials and protective layers can we achieve the highest corrosion resistance for brake units in marine applications achieve.
The suitability of stainless steel for marine applications varies. 1.4301 (304) is often insufficient; alloys such as 1.4404 (316L) or duplex steels (e.g. 1.4462) offer better protection. Duplex steels with a PREN value over 32 are advantageous due to their resistance to pitting corrosion in chloride-containing media, an important aspect for every corrosion-resistant brake unit for marine applications. A corrosion-resistant gear unit also benefits from it. Selection of highly alloyed stainless steels such as 1.4404 (316L) or duplex steels (e.g. 1.4462) for optimal protection of
- Auswahl hochlegierter Edelstähle wie 1.4404 (316L) oder Duplex-Stähle (z.B. 1.4462) für optimalen Schutz von of corrosion-resistant brake units for marine applications..
- Preference for duplex steels with a PREN value over 32 to avoid pitting corrosion in chloride-containing environments.
- Application of robust multi-layer coating systems, for example, a combination of zinc-rich epoxy primer and polyurethane topcoat.
- Achieving protection durations of over 15 years according to ISO 12944 (Category C5-M) to extend maintenance intervals for of corrosion-resistant brake units.
- Implementation of redundant sealing systems to prevent internal corrosion from invading saltwater.
- Use of high-quality sealing materials such as FKM (Viton®), which are temperature resistant up to 200°C.
- Constructive design with double sealing lips and grease chambers to protect internal components and maximize the lifespan of the brake unit in marine applications.
Robust multi-layer systems are superior to single layers. A typical combination is a zinc-rich epoxy primer with a polyurethane topcoat. This allows for protection durations of over 15 years according to ISO 12944 (Category C5-M), extends maintenance intervals, and reduces costs for seawater-resistant brake systems..
Internal corrosion from invading saltwater leads to failures. Therefore, redundant sealing systems are critical. High-quality materials such as FKM (Viton®), which are temperature resistant up to 200°C, and constructions with double sealing lips and grease chambers protect internal components and maximize the lifespan of a corrosion-resistant brake unit for marine applications..Optimizing: How intelligent design and system integration enhance the performance of marine brake units. Standard designs complicate the replacement of brake pads on swaying platforms.
Modular constructions, where assemblies like brake calipers can be quickly exchanged, reduce maintenance time by up to 60%, a principle of Modulare Konstruktionen, bei denen Baugruppen wie Bremszangen schnell tauschbar sind, reduzieren die Wartungszeit um bis zu 60%, ein Prinzip von WBA shaft brake systems, which are often executed as corrosion-resistant brake units for marine applications .
- Developing modular constructions that enable quick replacement of assemblies such as brake calipers and reduce maintenance time by up to 60%. of corrosion-resistant brake units for marine applications. um bis zu 60% reduzieren.
- Application of smooth surfaces and anti-fouling coatings or copper-nickel alloys to minimize biofouling by marine organisms by over 80%.
- Integration of sensors to monitor lining thickness and pressure, with data transmission to the ship’s control system for continuous status reporting.
- Use of spring-applied brakes that operate on the fail-safe principle to ensure a secure hold even in case of power failure.
- Improving the maintenance-friendliness of brake units for marine applications on swaying platforms through easily accessible and replaceable components.
Biofouling by marine organisms, especially in warm waters, can disrupt braking function. Smooth surfaces, anti-fouling coatings, or copper-nickel alloys for mounting components minimize this risk and reduce fouling by over 80%, relevant for the entire shipbuilding industry and the longevity of of corrosion-resistant brake units for marine applications..
Integrated sensors (layer thickness, pressure) ensure secure hold during power failure and status reporting with data transmission to the ship control system, as well as spring-applied brakes (fail-safe principle). This guarantees maximum safety during the installation of marine braking systems. Such brake units for marine applications are safety anchors, especially when it comes to corrosion-resistant braking systems .Validation: Through which tests and certifications we ensure the maritime suitability of our of corrosion-resistant brake units products.
Seawater resistance requires resistance to salt mist. A passed test according to ASTM B117 for over 1000 hours without significant corrosion (rust grade Ri3, ISO 4628-3) is the minimum standard. Such tests prove the long-term durability of coatings and materials and ensure the field reliability of of corrosion-resistant brake units for marine applications..
tests under simulated marine conditions are essential for maritime applications; pure dry function is not sufficient. Corrosion-resistant brake units for marine applications are validated in immersion tests and dynamic load cycles, partly under flooding conditions (similar to requirements for underwater brakes), validated with, for example, 500,000 load cycles.
Recognized classification societies confirm suitability for maritime requirements. Collaboration with DNV, ABS, or Lloyd’s Register, which verify and certify design, manufacturing, and material quality of of corrosion-resistant brake units for marine applications. products, provides independent confirmation. Thus, such braking systems for maritime applications meet the highest standards.Conclusion and outlook
The selection of the appropriate corrosion-resistant brake unit for marine applications. is crucial for safety and efficiency of maritime operations. Material expertise, thoughtful design, intelligent design features, and rigorous testing distinguish ATEK marine brakes. Effective corrosion protection for marine applications, especially for braking units for maritime use, requires multi-layer solutions. Rely on partners who understand this complexity. Contact us for customized advice on selecting the optimal corrosion-resistant brake unit for your specific marine applications and to secure your maritime assets.
