Additive Manufacturing of a Vehicle Brake System Component

Marques, José Diogo Sena Luz Da Cruz

http://hdl.handle.net/10400.8/5538

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Authors

Marques, José Diogo Sena Luz Da Cruz

Advisor(s)

Alves, Maria Leopoldina Mendes Ribeiro de Sousa

Sousa, Carlos Manuel Pereira Costa e

Abstract(s)

The present project aims to study the applicability of additive manufacturing (AM) in the automotive industry, namely, the applicability of AM in car parts production. A commercial vehicle can be described as a set of systems, all integrated and communicating each other, with a common goal, move you from point A to point B as secure as possible. The present study focused on the manufacture by AM of a part from one of the systems integrated in the vehicle, namely a brake calliper, component of the brake system. The Selective Laser Melting (SLM) was the AM process that was used to manufacture the part. It is important to understand that nowadays, a great level of evolution is occurring in the automotive industry. Some new technology had its origins in the racing world. Race teams lead by the big manufacturing car companies have the know-how and the opportunities to try and develop new technologies. This leads to a development in manufacturing processes associated with new components and materials. After some perfecting, the components and manufacturing techniques used in the racing industry find its way into the commercial vehicle market, leading to the endless flow of innovation that we see nowadays. The component selected to be developed and furthermore manufactured using AM was a brake calliper, part of the braking system of a racing vehicle. The new SLM produced brake callipers will be used in the Formula Student racing platform.