Modern brake discs are composed of several parts consisting of different materials, such as an aluminum disc chamber which is connected with a cast iron friction ring through steel inlays. Most of these processes are very complex and expensive. In order to ensure a reliable and cost-effective compound casting process of steel inlays and an AlSi alloy, a method is required which can be integrated in the normal production process. The investigations discussed in this paper are laboratory-scaled tests. These results have to be extended to industrial scale.

Samples out of sand casting and die casting were studied. Crucial for a good bond between steel inserts and AlSi alloy is the lowest possible temperature difference and a maximum surface roughness of the steel inlays. By the use of a coating it is important to ensure that this coating has a higher hardness than the casted material.

Ralf Kaiser, Gotthard Wolf - Foundry-Institute, TU Bergakademie Freiberg