Laser Cleaning of Grey Cast Iron Automotive Brake Disc: Rust Removal and Improvement in Surface Integrity

Yerowo Ogbekene, Pratik Shukla, Yu Zhang, Xiaojun Shen, Subramanian Prabhakaran, Sivaperuman Kalainathan , Kiran Gulia, Jonathan Lawrence

Research output: Contribution to journalArticle

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Abstract

There is a great need for removal of rust and surface damage from corroded engineering parts. This enables the retention of strength and increased longevity of metals and alloys in general. The use of lasers for cleaning, polishing and ablation has proven to be effective and promising overtime. This research is focused on a parametric study of laser cleaning a corroded grey cast iron brake disc. A continuous wave CO2 laser having a wavelength of 10.6µm was used for the study. A systematic approach was employed for the experiments where one parameter was changed while other parameters remained constant. Additional effects of laser cleaning were predicted by a Gaussian process regression approach. The results revealed that the best parameters which cleanly removed the rust were 60W of laser power, 900mm/s traverse speed, and a spot size of 722µm. The enhancement of surface microhardness of laser cleaned specimen was 37% compared to the rusted specimen surfaces. The roughness of the laser cleaned surface was, 1.29µm while the rusted surface comprised of 55.45µm (Ra). Microstructural analysis showed a presence of randomly distributed graphite flakes surrounded by a pearlitic matrix containing ferrite and cementite after laser cleaning. This was similar to that of the un-rusted surface. The hardness, roughness and microstructural content were in close relation with the respective properties of the unrusted automotive brake disc. This showed that the mechanical and physical properties of the brake disc were not altered negatively during the laser cleaning process. Implementation of the laser-cleaning technique in automotive and manufacturing industries should be embraced as it provides a faster, safer and cheaper way of enhancing the surface integrity of components and also paves way for other surface enhancement methodologies to be applied such as blast cleaning or laser shock cleaning for inducing extra strength, by beneficial residual stresses.
Original languageEnglish
Pages (from-to)155 - 180
Number of pages25
JournalInternational Journal of Peening Science & Technology
Volume1
Issue number2
Early online date30 Nov 2018
Publication statusPublished - 30 Nov 2018

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Cast iron
Brakes
Cleaning
Lasers
Blast cleaning
Surface roughness
Continuous wave lasers
Ablation
Polishing
Microhardness
Ferrite
Residual stresses
Graphite
Physical properties
Hardness
Wavelength
Mechanical properties
Metals

Bibliographical note

Copyright © and Moral Rights are retained by the author(s) and/ or other copyright owners. A copy can be downloaded for personal non-commercial research or study, without prior permission or charge. This item cannot be reproduced or quoted extensively
from without first obtaining permission in writing from the copyright holder(s). The content must not be changed in any way or sold commercially in any format or medium without the formal permission of the copyright holders.

Keywords

  • Laser Cleaning
  • Grey Cast Iron
  • Surface Integrity

Cite this

Laser Cleaning of Grey Cast Iron Automotive Brake Disc : Rust Removal and Improvement in Surface Integrity. / Ogbekene, Yerowo ; Shukla, Pratik; Zhang, Yu; Shen, Xiaojun; Prabhakaran, Subramanian; Kalainathan , Sivaperuman; Gulia, Kiran ; Lawrence, Jonathan.

In: International Journal of Peening Science & Technology, Vol. 1, No. 2, 30.11.2018, p. 155 - 180.

Research output: Contribution to journalArticle

Ogbekene, Yerowo ; Shukla, Pratik ; Zhang, Yu ; Shen, Xiaojun ; Prabhakaran, Subramanian ; Kalainathan , Sivaperuman ; Gulia, Kiran ; Lawrence, Jonathan. / Laser Cleaning of Grey Cast Iron Automotive Brake Disc : Rust Removal and Improvement in Surface Integrity. In: International Journal of Peening Science & Technology. 2018 ; Vol. 1, No. 2. pp. 155 - 180.
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AU - Prabhakaran, Subramanian

AU - Kalainathan , Sivaperuman

AU - Gulia, Kiran

AU - Lawrence, Jonathan

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N2 - There is a great need for removal of rust and surface damage from corroded engineering parts. This enables the retention of strength and increased longevity of metals and alloys in general. The use of lasers for cleaning, polishing and ablation has proven to be effective and promising overtime. This research is focused on a parametric study of laser cleaning a corroded grey cast iron brake disc. A continuous wave CO2 laser having a wavelength of 10.6µm was used for the study. A systematic approach was employed for the experiments where one parameter was changed while other parameters remained constant. Additional effects of laser cleaning were predicted by a Gaussian process regression approach. The results revealed that the best parameters which cleanly removed the rust were 60W of laser power, 900mm/s traverse speed, and a spot size of 722µm. The enhancement of surface microhardness of laser cleaned specimen was 37% compared to the rusted specimen surfaces. The roughness of the laser cleaned surface was, 1.29µm while the rusted surface comprised of 55.45µm (Ra). Microstructural analysis showed a presence of randomly distributed graphite flakes surrounded by a pearlitic matrix containing ferrite and cementite after laser cleaning. This was similar to that of the un-rusted surface. The hardness, roughness and microstructural content were in close relation with the respective properties of the unrusted automotive brake disc. This showed that the mechanical and physical properties of the brake disc were not altered negatively during the laser cleaning process. Implementation of the laser-cleaning technique in automotive and manufacturing industries should be embraced as it provides a faster, safer and cheaper way of enhancing the surface integrity of components and also paves way for other surface enhancement methodologies to be applied such as blast cleaning or laser shock cleaning for inducing extra strength, by beneficial residual stresses.

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