Cold Spray Remanufacturing of Brake Disks: Circular Solutions for Sustainable Mobility

We are developing an innovative remanufacturing concept for automotive brake disks based on cold spray technology, aligned with circular economy and resource efficiency goals. Cold spray enables high-performance metallic coatings to be deposited at low temperatures, allowing for:

• Full restoration of worn brake disk surfaces to OEM specifications or better

• Significant extension of component lifespan

• Reduction in material waste and CO₂ emissions compared to producing new disks

Our cold spray facilities are equipped to handle key materials used in brake disks (e.g., cast iron, 316L stainless steel) and enable:

• Damage-free, solid-state deposition

• High adhesion strength and dense, durable coatings

• Tailored surface properties for wear and corrosion resistance

Project Aims:
We aim to contribute to an integrated remanufacturing approach that includes:

• Developing process chains combining disassembly, cleaning, cold spray restoration, quality control, and reassembly

• Demonstrating industrial-scale feasibility for brake disks as a pilot use case

• Conducting life-cycle assessments (LCA) and techno-economic analysis (TEA)

• Establishing protocols for standardization and certification of remanufactured parts

Looking For:

• Coordinators with experience in large-scale Horizon consortia

• Industrial partners (automotive OEMs, brake system manufacturers, remanufacturing specialists)

• Digital solution providers (for monitoring, traceability, and process optimization)

• Sustainability and policy experts (LCA, circular economy metrics)

Our Contributions:

• Access to state-of-the-art cold spray infrastructure

• Expertise in material characterization, surface engineering, and process validation

• Participation in prototype trials and pilot-scale demonstrations

• Contribution to standardization, certification, and industrial upscaling