Description:FIELD OF THE INVENTION
This invention relates to A modern machine to speed up baking process, A process to utilize waste materials for structural purpose
BACKGROUND OF THE INVENTION
Particularly susceptible to rust are automotive braking systems as it shortens the life of vital components and may compromise safety. The Society of Automobile Engineers (SAE) estimates that the average corrosion rate of car components is around 10-12 m/year, roughly equivalent to that of marine environments. Among the most affected are cast iron and steel parts, particularly those employed in the braking system. While a little film of rust on the brake rotor after rain is usually innocuous and dissipates when you apply the brakes, more serious corrosion needs a treatment. A major concern is the corrosion of brake pads, especially the backing plate, which is the structural support holding the friction material in place. Usually made of steel, the backing plate is quite susceptible to corrosion in hot and humid conditions. Apart from compromising the structural integrity of the plate, this degradation greatly affects the adhesion between the backing plate and the friction material. Partial or total separation of the friction layer might compromise vehicle safety by causing more effective breaking and longer stopping distances.
Given the natural limitations of conventional steel in terms of corrosion resistance, investigating innovative materials and protective methods is absolutely essential. Two encouraging ways to lower corrosion are selecting corrosion-resistant steel alloys with outstanding mechanical and chemical properties and using functional surface coatings to provide a barrier shielding the backing plate from the environment. The evolution and use of such technology is therefore necessary if modern braking systems are to last longer, be more reliable, and be safer.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
Available are galvanized backing plates, which use a zinc electroplated layer to offer galvanic protection; nevertheless, their corrosion resistance is low, especially in hostile environments. Though zinc plating slows the corrosion process, in severe conditions such continuous exposure to moisture or salt it is not durable enough. Nickel alloy coatings have shown better resistance to wear and corrosion; several deposition methods including thermal spraying, chemical vapor deposition, and physical vapor deposition have been studied. These methods, however, can occasionally mean high setup expenses, limited coating uniformity on complex geometries, or both.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
FIGURE 1: PERSPECTIVE VIEW
FIGURE 2: TOP VIEW
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Available are galvanized backing plates, which use a zinc electroplated layer to offer galvanic protection; nevertheless, their corrosion resistance is low, especially in hostile environments. Though zinc plating slows the corrosion process, in severe conditions such continuous exposure to moisture or salt it is not durable enough. Nickel alloy coatings have shown better resistance to wear and corrosion; several deposition methods including thermal spraying, chemical vapor deposition, and physical vapor deposition have been studied. These methods, however, can occasionally mean high setup expenses, limited coating uniformity on complex geometries, or both.
Electroless nickel (EN) plating distinguishes itself from the other choices as it can produce uniform and sticky coatings without using an outside power source. But under severe conditions, even traditional single-layer EN coatings might not offer enough long-term protection. Advanced solutions are thus being investigated, including duplex or multi-pass electroless Ni coatings stretched with nanoparticles (ZrO2/TiO2). Though their outstanding electrochemical stability is generally known, further study is still required to identify the optimal combinations and layer designs for consistently high corrosion resistance. Present choices do not completely satisfy the demand for long-lasting, reasonably priced, scalable, corrosion-resistant coatings for brake pad backing plates.
By means of a sophisticated electroless nickel-phosphorus (Ni-P) composite coating enhanced with nanoparticles such ZrO2 and TiO2, the present invention aims to enhance the corrosion resistance of metallic car components. This novel coating structure, made up of layered combinations including Ni-P-ZrO2/Ni-P-TiO2 and Ni-P-TiO2/Ni-P-ZrO2, shows more corrosion resistance than commercial electroplated coatings and conventional galvanization now used in the vehicle industry.
Improved performance results from higher electrochemical stability and standard corrosion potentials of the incorporated nanoparticles, which operate as active barriers against corrosive circumstances. The suggested coating offers a long-lasting, affordable, environmentally benign, and easily adjustable answer to common issues with steel components used in brake pad backing plates. The coating technique described here is very flexible and may be extended to protect several other crucial automotive components in severe weather conditions, including gearbox components, fuel system components, turbochargers, and other cast-iron or steel components. By significantly increasing the service life and dependability of essential components, the invention increases material sustainability, reduces maintenance expenses, and strengthens vehicle safety.
, Claims:1. A corrosion-resistant coating for metallic automotive components, comprising:
a multilayer electroless nickel-phosphorus (Ni-P) composite structure, wherein:
• at least one layer includes uniformly dispersed zirconium dioxide (ZrO₂) nanoparticles;
• at least one other layer includes uniformly dispersed titanium dioxide (TiO₂) nanoparticles;
wherein the multilayer structure exhibits enhanced corrosion resistance compared to conventional single-layer Ni-P coatings.
2. The coating as claimed in claim 1, wherein the nanoparticles have an average size ranging from 5 to 50 nanometers.
3. The coating as claimed in claim 1, wherein the multilayer structure comprises alternating layers of Ni-P-ZrO₂ and Ni-P-TiO₂.
4. The coating as claimed in claim 1, wherein the total thickness of the multilayer structure ranges from 10 to 50 micrometers.
5. The coating as claimed in claim 1, wherein the Ni-P layers have a phosphorus content between 6% and 12% by weight.
6. The coating as claimed in claim 1, wherein the multilayer structure is deposited on a steel substrate used in automotive brake pad backing plates.
7. The coating as claimed in claim 1, wherein the multilayer structure provides a corrosion potential shift of at least 100 mV towards the noble direction compared to uncoated steel, as measured by electrochemical testing.