Method to produce high corrosion and wear resistant cast iron components by using laser cladding

A method to produce a wear and corrosion resistant coating system onto a surface of a brake disc, the method comprising the following steps:

• (1) providing the brake disc having the surface to be coated with a coating system,
• (2) selecting a dedicated material for producing one or more coating layers of the coating system,
• (3) producing onto the brake disc surface to be coated one or more coating layers of the coating system by using a laser cladding process, wherein the dedicated material selected in step (2) is used as a source material for the production of the coating layers,
• wherein for conducting step (3) a laser beam is positioned with respect to the brake disc surface to be coated in such a manner that an angle is formed between the laser beam and an axis perpendicular to the brake disc surface to be coated, and this angle is called a coating angle, and the coating angle is maintained during the production of the one or more coating layers at a value between 10° and 30°, and
• wherein the brake disc or at least the surface of the brake disc is made of an iron-based material or a steel material and wherein the dedicated material is fed into the laser beam above the brake disc, and
• wherein the coating system has a total thickness between 150 and 500 μm, a porosity according to ASTM E2109-09≤0.5% and average microhardness of 305 HV.