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Technical Note

Applicability investigation of alumina-titania based plasma spray coating on cast iron brake discs for battery electric vehicles

Ekrem Altuncu 1, Recep Akyüz2

1Sakarya App. Sci. Uni., Sakarya, Turkey                                                                                                           2TOFAŞ Turkish Automotive Company R&D Center, Bursa, Turkey



Plasma spray; 

Ceramic coating; 


Brake Discs

Automobile brake disc are subjected to cyclic thermal, mechanical and corrosive effects. In general, gray cast iron grades are preferred as disc brake materials. Lamellar cast iron disc brakes have a limited lifetime and are replaced periodically during the maintenance-service process. With the growing interest in the number of Battery Electric Vehicles (BEV), there is a need for disc brake with longer service life on discs. Therefore, in the automotive sector, in line with increasing competition and user demands, there is an interest in new coating types and materials with corrosion free properties, a longer service life and high brake performance. Wear and corrosion resistant plasma spray coatings are the key to increasing the service life and braking performance of cast iron discs. In this study, the discs (GG20) are coated with Alumina- Titania based ceramic material by atmospheric plasma spray method. The ceramic coated disc brakes were installed on the road driving test vehicle and disc brake thickness reduction were measured periodically according to wear test plan throughout 20.000 km. The test results show that the ceramic coating provides 18 times more wear resistance compared to uncoated disc brake. In addition, coated disc brakes exhibited superior performance in corrosion tests. As a result of the investigations carried out on disc brakes, it is understood that plasma spray ceramic coatings can be used alternatively in brake disc systems.

© 2019 MIM Research Group. All rights reserved.


31/12/2020 Most Cited Award: 

According to the Editorial Board evaluation, the paper authored by Nelson Batista, Rui Melicio, Victor Mendes entitled as “Darrieus vertical axis wind turbines: methodology to study the self-start capabilities considering symmetric and asymmetric airfoils" is awarded the 2020 Most Cited Paper Award of Research on Engineering Structures and Materials (RESM).

31/12/2020 Best Paper Award:

According to the Advisory Board decision, the paper authored by Marcelo Mesquita do Amaral, Matheus Wanglon Ferreira and Mauro de Vasconcellos Real entitled as “A simplified method for analysis of reinforced concrete beams exposed to fire situation” is awarded the 2020 Best Paper Award of Research on Engineering Structures and Materials (RESM).

02/11/2020 Indexed by SCOPUS: We are informed that our journal is accepted to be included in the SCOPUS Index. See mews for more info.

20/08/2020 Collaboration for IMSTEC 2020: Editorial Board of our journal and Organizing Committee of the 5. International Conference on Material Science and Technology (IMSTEC 2020) have agreed to collaborate. Extended versions of the selected papers from the conference will be published in our journal. For more see Events.

13/11/2019 Data articles as a new type of submision: Editorial Board of our journal have decided to accept a new type of submission: data articles. The focus of these papers is only on data and how it is collected but not on its interpretation and drawn conclusions. For more see News section.

(More details of the news may be given in the News section)

For more see News...


2020 Most Cited Paper Award:

The paper authored by Nelson Batista, Rui Melicio, Victor Mendes entitled as “Darrieus vertical axis wind turbines: methodology to study the self-start capabilities considering symmetric and asymmetric airfoils" is awarded the

2020 Best Paper Award:

The paper authored by Ahsen Ünal, Işıl Özer, Melek Erol Taygun, Sadriye Küçükbayrak entitled as “Fabrication and in-vitro evaluation of copper doped bioactive glass/polymer composite scaffolds for bone tissue engineering” is awarded the 


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