Disc brakes wear during braking events and release airborne particulates. These particle emissions are currently one of the highest contributors to non-exhaust particle emissions and introduce health hazards as well as environmental contamination. To reduce this problem, wear and corrosion-resistant disc coatings have been implemented on grey cast iron brake disc rotors by using various deposition techniques such as thermal spraying and overlay welding. High thermal gradients during braking introduce risks of flaking off and cracking of thermally sprayed coatings with adhesive bonding to the substrate. Overlay welding by laser cladding offers metallurgical bonding of the coating to the substrate and other benefits that motivate laser cladding as a candidate for the coating of the grey cast iron brake discs. This study aims to investigate the effect of laser cladding on the thermal and thermo-structural performance of the coated grey cast iron brake discs. Therefore, thermal and thermo-stress analysis with COMSOL Multiphysics 5.6 software is performed on braking events of grey cast iron brake discs as non-coated – reference and laser cladding coated with stainless steel welding consumables. The Results demonstrated that surface temperatures were more localised, overall higher in the laser cladded coating with over three times the stresses attained of reference grey cast iron discs. The output of the simulations has been compared by tests found in the literature. Laser cladding presented higher reliability and braking performance, nonetheless requiring the evaluation of its thermal impact on other system components.

盘式制动器在制动过程中会磨损并释放出空气中的微粒。目前，这些颗粒物排放是非排放颗粒物排放的最大贡献者之一，并带来健康危害以及环境污染。为了减少这个问题，已经通过使用各种沉积技术（例如热喷涂和堆焊）在灰口铸铁制动盘转子上实施了耐磨和耐腐蚀的盘涂层。制动过程中的高热梯度会导致剥落和粘合剂粘结在基材上的热喷涂涂层破裂的风险。通过激光熔覆进行的堆焊可将涂层冶金结合到基材上，并具有其他优点，可激发激光熔覆作为灰口铸铁制动盘涂层的候选材料。这项研究旨在研究激光熔覆对灰口铸铁制动盘热性能和热结构性能的影响。因此，使用COMSOL Multiphysics 5.6软件对无涂层的灰铸铁制动盘的制动事件进行了热应力和热应力分析–参考涂层和激光熔覆了不锈钢焊接材料。结果表明，激光熔覆涂层的表面温度更局限，整体温度更高，其应力是参考灰口铸铁圆盘的三倍以上。模拟的输出已通过文献中的测试进行了比较。激光熔覆具有更高的可靠性和制动性能，但仍需要评估其对其他系统组件的热影响。