Learn how to extend the life of your systems and minimize downtime with the right brakes and coatings.
What are the main advantages of a surface-coated brake for abrasive applications?
A surface-coated brake for abrasive applications offers significant advantages such as a substantially extended lifespan, even under extreme conditions. Additionally, it leads to reduced maintenance costs, for example, by reductions of up to 40% in certain applications, and ensures a more consistent braking performance and higher operational safety.
Which coating technologies are particularly well-suited for brakes in abrasive environments?
For the protection of brakes in abrasive environments, technologies such as High-Velocity Oxy-Fuel (HVOF) for extremely hard layers, which powder coating with inductive melting for robust and thick layers, as well as two-layer systems, which combine corrosion protection with wear resistance, have proven to be particularly effective.
How does ATEK Drive Solutions ensure the quality and longevity of its coated brakes?
ATEK Drive Solutions relies on comprehensive quality controls throughout the coating process. This includes layer thickness measurements, adhesion tests, and specific tests for abrasion resistance, to guarantee consistently high quality and performance of the surface-coated brake for abrasive applications .
Can ATEK develop customized coatings for brakes that are exposed to specific abrasive conditions?
Yes, ATEK Drive Solutions specializes in developing customized drive solutions. This includes tailor-made coatings for brakes that are precisely matched to the specific operating conditions and the type of abrasion in your application to achieve maximum protection and performance.
Why is the surface pre-treatment so important for the performance of a coated brake?
The surface pre-treatment, meaning the cleaning and activation of the brake surface, is fundamental for the later performance of the coating. It ensures an optimal adhesion of the protective layer and can account for up to 50% of the overall performance and longevity of the coating, especially in a surface-coated brake for abrasive applications.
How do two-layer coating systems improve the protection of brakes in harsh environments?
Two-layer systems combine the strengths of various materials. Typically, a base layer provides excellent corrosion protection and adhesion, while a special top layer offers high wear resistance against abrasion. This combination can reduce disc wear by up to 80%, for example.
What impact does a so-called transfer film have on the lifespan of a coated brake disc?
A transfer film that forms from material of the brake pad on the brake disc acts as an active protective mechanism. It reduces direct contact between friction partners and thus minimizes wear on the actual brake disc coating, which extends the lifespan of the brake..
How does ATEK support companies beyond mere brake supply in challenges in abrasive environments?
As a system provider, ATEK considers the entire industrial drive train.We offer comprehensive consulting and can optimally align the brake solution with gear boxes, motors, and the specific application. This integrated approach can increase the overall efficiency of the system by up to 10% and maximize reliability in abrasive environments.
Surface coatings are essential for brakes in abrasive environments as they significantly extend the lifespan – for example, doubling it in the cement industry – and can reduce maintenance costs by up to 40%. Advanced technologies such as können.
Fortschrittliche Technologien wie HVOF coatings can triple the service life of brake components, while two-layer systems reduce disc wear by up to 80% and thus maximize the performance of a surface-coated brake for abrasive applications .
A detailed analysis of the operating conditions and a careful surface pre-treatment are crucial for success. System providers like ATEK offer customized solutions and an integrated approach, which optimizes the overall efficiency of the drive train.Discover the secrets of long-lasting brakes in abrasive environments. This article shows you how to choose the right surface coating to reduce wear and optimize performance.
Abrasive environments impose extreme demands on brakes. The right surface coating is crucial for durability and reliability. We show you what matters and how ATEK Drive Solutions can support you with tailored solutions. Contact us at /contact for personalized consulting.
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Understand: Why surface protection is crucial for brakes in abrasive environments.
The constant threat of abrasion
Brakes exposed daily to fine, aggressive particles suffer from significant wear. The choice of the appropriate surface coating significantly determines the lifespan and reliability, especially with a surface-coated brake for abrasive applications. Experience in the cement industry shows, for example, that specific hard material layers can double service lives. Optimize industrial brakes.
More than just scratch resistance
Frequent brake changes due to wear and corrosion incur costs. A high-quality brake coating offers not only abrasion protection but also corrosion resistance. This can reduce maintenance costs by up to 40%, especially in wet or chemically loaded environments, such as sewage treatment plants. A comprehensive protection strategy for brakes in abrasive environments takes all environmental influences into account.
The basis for performance
The full performance capability of brakes under the harshest conditions also depends on the surface. The surface texture influences friction behavior and heat dissipation. A surface-coated brake optimized for abrasive use can improve braking consistency by 15%. kann die Bremskonstanz um 15% verbessern. Optimized surfaces contribute to consistent braking performance and safety.Analyze: Recognizing abrasion mechanisms and their effects on brake components
Hard particles, large impact
When a hard particle strikes a brake surface, it can tear out material, create grooves, or embed itself, causing further damage. In foundries, for example, quartz sand particles reduce the lifespan of unprotected brakes by over 60%. Understanding the specific abrasive medium is fundamental to solution finding, especially when it comes to a surface-coated brake for abrasive applications.
Consequences of inadequate protection
An early brake failure can trigger a chain reaction: starting with reduced efficiency, through unplanned downtimes, to safety risks and production losses of thousands of euros per hour. Preventive protection through special brake coatings represents an important investment.
Wear on disc and pad
Abrasion affects not only the brake disc; brake pads are also heavily stressed. This can lead to a changed friction pairing and unpredictable braking behavior. A well-matched surface treatment, as provided by ATEK for wear-resistant brake discs protects both components. A system approach considers the protection of the entire friction pairing, especially for brakes in rough environments.Select: Targeted use of key technologies for coated brakes
Thermal spraying processes like HVOF
Extremely hard and dense protective layers can be achieved, for example, through High-Velocity Oxy-Fuel (HVOF). This process produces layers with over 1200 HV hardness, which can extend the lifespan of brake components in steelworks by a factor of 3. HVOF layers provide effective protection against severe abrasive wear, ideal for achieving extremely hard and dense protective layers through HVOF. surface-coated brake for abrasive applications.
- Erzielung extrem harter und dichter Schutzschichten durch HVOF.
- Generating layers with a hardness of over 1200 HV.
- Potential to triple the lifespan of brake components in steelworks.
- Effective protection against severe abrasive wear, a must for brakes in abrasive environments.
- Ensuring high-quality coatings with excellent adhesion.
- Ideal for applications with high mechanical loads and abrasion, as encountered with a surface-coated brake for abrasive applications.
powder coating with inductive melting
For thick, resilient, and well-adhered layers, powder coating combined with inductive melting is suitable. This process, used by Venjakob Maschinenbau for chassis parts, can significantly increase resistance to stone impact and abrasion. It allows robust protective layers even on complex geometries of brake components with surface treatment.
Two-layer systems: Better safe than sorry
Two-layer systems can enhance protection. A patented process uses a base layer for corrosion protection and adhesion, combined with a thin, hard friction layer. This combination, often only 30-50µm thick, can promote the formation of a protective transfer film and reduce disc wear by up to 80%. Thoughtful layer combinations optimize protection and performance for brakes with special coating. Learn more about modern brake technology.
Importance of pre-treatment
A high-performance coating requires a carefully prepared surface. The cleaning and activation of the surface are fundamental for adhesion and longevity. Companies like Venjakob emphasize that pre-treatment accounts for up to 50% of later performance. An optimal pre-treatment is crucial for the longevity of the coating of a surface-coated brake for abrasive applications.Individualize: Configure the optimal coating protection for your specific application
Analysis of operating conditions
The selection of the optimal brake coating depends on factors such as the type of abrasive, temperature, load, environmental humidity, and chemical influences. For brakes in the paper industry, which are exposed to a wetter and dustier environment, a special nickel-based coating could extend maintenance intervals by 70%. A detailed needs analysis is fundamental to success of a surface-coated brake for abrasive applications.
- identification of the specific type of abrasive in the application.
- Analysis of the prevailing operating temperatures and temperature fluctuations.
- Assessment of the mechanical loads and stresses on the brake.
- Consideration of environmental humidity and possible condensation.
- Detection of chemical influences from aggressive media or cleaning agents.
- Conducting a detailed needs analysis as a basis for the selection of protective layers for brakes.
- Example: Extending maintenance intervals by 70% in the paper industry through a tailored nickel-based coating for a wear-resistant brake.
When standard is not enough
When standard coatings do not meet the extreme requirements of an application, custom solutions are required. ATEK Drive Solutions, for example, develops heavy-duty industrial brakes customized coatings that are precisely tuned to the operating conditions in the rolling mill – often the basis for a high-performance surface-coated brake for abrasive applications. Customization can maximize the protection factor.
The interplay of material and layer
Not only the coating but also the base material of the brake is responsible for protection. The combination of a robust stainless steel base body and a hard material coating can increase the lifespan by a factor of 2.5 in food processing, where aggressive cleaning agents are used. The synergy of base material and coating is of great importance for the surface protection of brakes. Discover options for stainless steel brake discs.Optimize: Achieve maximum braking performance and lifespan with a systems approach
The role of the transfer film
A protective transfer film plays an important role in some coating concepts. As described in patent DE102018122234B4, particles in the friction layer wear material from the brake pad. This forms a thin film on the disc, reducing direct contact and thus the wear of the brake disc coating. A stable transfer film acts as an active protection mechanism, especially in a surface-coated brake for abrasive applications.
Quality assurance in the coating process
To ensure the performance of each coated brake, quality controls are essential. These include layer thickness measurements, adhesion tests, and abrasion resistance tests. ATEK uses standardized testing procedures to ensure consistently high quality of the surface-coated brake for abrasive applications coating. Continuous quality control ensures performance.
ATEK: Your partner for the entire drive train
A systems approach can be superior to isolated solutions. As a system provider, ATEK delivers not only brakes but complete drive solutions including Gear Boxes and motors. This expertise allows for the optimal alignment of the brake coating with the overall system, resulting in efficiency increases of up to 10%, which is beneficial for every surface-coated brake for abrasive applications . An integrated approach serves to optimize the overall system.
