Recently, environmental concerns have initiated intensive research and development in the field of friction brake systems with the aim to minimize particle emission. First brake systems that include thermally sprayed protective coatings on grey cast iron brake disks have been introduced in automotive industries and have proven suitability to strongly reduce particle emission. However, there is desire to use materials that show better environmental compatibility and lower price and to use processes that permit improved characteristics of protective coatings at reduced production costs. Different approaches concerning choice of base and coating materials as well as production processes are discussed with respect to technological, economic and ecological aspects. Besides grey cast iron also aluminum alloys are considered as base materials. For coating production HVOF spraying and laser cladding offer specific advantages and recent progress concerning the expansion of their production rate limitations is presented. Finally, novel feedstock materials that show excellent compatibility with stainless steel or aluminum alloy matrices have been developed and applied for coating production.

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