Title: Thermo-mechanical analysis of Ni-Cr coated brake discs using finite element method

Authors: Rakesh Chaudhari; Rajendra Shimpi; Dinesh Shinde

Addresses: Mechanical Engineering Department, MPSTME NMIMS, Shirpur, Maharashtra, 425405, India ' Advance Manufacturing Department, Symbiosis Skills and Professional University, Pune, Maharashtra, 412108, India ' R&D Department, Endurance Technologies Ltd., Chhatrapati Sambhajinagar, Maharashtra, 431001, India

Abstract: The brake disc is key element of any vehicle for slowing down or stopping the speed of wheel. The widely used brake disc materials pose some challenges in terms of fuel consumption due their specific gravity. The sue of lightweight cast iron, aluminium alloy, titanium alloy, ceramics and composites are restricted by low melting point and high cost. The present work attempts to use hardened mild steel for the brake disc as it possesses high strengths and good machinability. Finite element analysis was carried out on steel plate without any coating and coated with wear-resistant Ni-Cr material. The solid state thermal and structural investigation was carried out on together the plates to investigate the hotness, total heat flux, total deformation and life expectancy of the brake disc. The important enhancement in the performance is observed in the disc after coating.

Keywords: brake disc; coating; deformation; heat flux; mild steel; wear.

DOI: 10.1504/IJCMSSE.2026.154228

International Journal of Computational Materials Science and Surface Engineering, 2026 Vol.12 No.4, pp.273 - 283

Received: 17 Sep 2025
Accepted: 22 Jan 2026
Published online: 17 Jun 2026 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article