Life Cycle Assessment of the rapid coating process for brake discs

The automotive industry faces increasing pressure to reduce environmental impacts, particularly due to stringent regulations like the Euro 7 standards, which limit non-exhaust emissions from vehicles. This study presents a Life Cycle Assessment (LCA) of the High-Speed Laser Cladding (HSLC) process for coating brake discs, developed on the IANUS cell of Prima Additive s.r.l. The primary objective is to evaluate the environmental performance of this innovative coating process, focusing on Cumulative Energy Demand (CED) and Global Warming Potential (GWP). The LCA follows a cradle-to-gate approach, encompassing raw material extraction, production, and the HSLC process itself. Additionally, a streamlined cost analysis was conducted to estimate the added cost of coating the brake disc. The functional unit is a Grey Cast Iron (GCI) brake disc coated with 430L stainless steel and titanium carbide (TiC) powders. Data were collected from both specific industrial processes and literature sources to ensure representativeness. Literature indicates that the HSLC process significantly reduces the environmental impact during the use phase of brake discs by enhancing wear resistance and reducing particulate emissions. However, the production of raw materials for coating, particularly the 430L stainless steel powder, remains a critical factor. The analysis also reveals that the HSLC process itself is energy-intensive, with the laser source and associated chillers accounting for most of the electricity consumption. Nonetheless, the overall environmental impact of the HSLC process is relatively minor compared to the production of the GCI brake disc. The results highlight the necessity of considering the entire life cycle of automotive components to achieve substantial environmental improvements, beginning with end-of-life management. Indeed, refurbishing brake discs through laser cladding processes offers the greatest potential for reducing their environmental impact. Further research in this area should focus on analysing powder reuse and optimising process parameters to enhance material and energy efficiency of the HSLC process.