Thermo-mechanical analysis of Ni-Cr coated brake discs using finite element method

The brake disc is key element of any vehicle for slowing down or stopping the speed of wheel. The widely used brake disc materials pose some challenges in terms of fuel consumption due their specific gravity. The sue of lightweight cast iron, aluminium alloy, titanium alloy, ceramics and composites are restricted by low melting point and high cost. The present work attempts to use hardened mild steel for the brake disc as it possesses high strengths and good machinability. Finite element analysis was carried out on steel plate without any coating and coated with wear-resistant Ni-Cr material. The solid state thermal and structural investigation was carried out on together the plates to investigate the hotness, total heat flux, total deformation and life expectancy of the brake disc. The important enhancement in the performance is observed in the disc after coating.