The process chain
The WECODUR process chain consists of several steps. Customer-specific wear and corrosion protection coatings can be applied. The individual process steps are illustrated below using the example of the refinement of conventional grey cast iron brake discs.
With an optional pre-treatment by grinding, the geometry of the brake disc (shape and position tolerances) can be improved in such a way that the subsequent coatings do not have to fill up the unevenness of the surface. This reduces the material consumption in the coating processes and significantly shortens the processing time while also improving cost efficiency.
WECODUR coating as corrosion protection
WECODUR technology is also used to apply an anti-corrosion coating. In contrast to conventional corrosion protection methods, this technology is also characterized by a metallurgical bonding to the workpiece.
WECODUR coating as wear protection
A wide range of material combinations are available for the application of a wear protection layer in order to best meet different customer requirements. If desired, this also allows brake disc service lives over the entire product life cycle (of the car).
To adjust the shape and position tolerances as well as the surface quality, the coating system is grinded according to the customer requirements. A specially developed diamond grinding process with double-sided kinematics is used. Due to the integrated process adjustments between coating and finishing, the smallest possible grinding allowance can be achieved.
Quality control is an integral part of the WECODUR process chain. This includes both, in-process and downstream measurements. Already during the production process (coating), extensive in-process control such as melt pool monitoring is carried out. Furthermore, all quality-relevant data is recorded and evaluated for each work piece to assure 100% quality during the production process. The final quality control ("post-process measurement") checks compliance with the drawing tolerances from the machining process, classically by evaluating process statistical characteristic values, and randomly checks the coating quality by means of destructive testing.