Surface modification of grey cast iron by laser cladding for automotive brake disc application

In this research, Laser Cladding (LC) of three different alloys powders, two iron-based (AISI 4140 and SS420) and a Cobalt-based (Stellite 6) was performed on a Grey Cast Iron (GCI) substrate. The Stellite 6, SS420, and AISI 4140 cladding samples were tested against a semi-metallic composite brake pin for friction and wear study using a pin-on-disc friction test rig (under dry-sliding conditions). The surface wettability tests were performed on GCI, and cladding discs showed Stellite 6 and AISI 4140 were hydrophobic while SS420 and GCI were hydrophilic. Stellite 6, SS420, and AISI 4140 had surface hardness values of 542.16 HV1, 689.56 HV1, and 719.50 HV1, respectively. The friction test indicated that AISI 4140 and Stellite 6 cladding discs could produce a stable Coefficient of Friction (CoF) and friction layer coverage. SS420 could not maintain a constant CoF for the entire test duration as the plowing effect of the wear particles damaged the friction layer created on its surface. Stellite 6's average CoF value was closest to that of the GCI disc, whereas AISI 4140 and SS420 were found to have a higher average CoF. The LC on grey cast iron reduced its wear rate, with AISI 4140 being the most wear-resistant cladding, followed by SS420 and Stellite 6, respectively. All three cladding layers exhibited three-body abrasive wear, with the rolling mechanism dominating the AISI 4140 surface and sliding on the remaining two.