How Porsche used HVOF to Revolutionise Brake Systems

What is HVOF?

HVOF stands for High Velocity Oxygen Fuel and refers to the process in which a thermal spray is used to coat a surface, improving its resistance to erosion and corrosion.

During HVOF, fuel and oxygen are fed into a combustion chamber where they ignite and combust continuously. The hot gases produced exit the chamber where they are combined with the coating material in powder form before being released as a high velocity spray stream. This spray stream is then directed towards a surface where, upon impact, the high kinetic and thermal energy forms a coating with extremely high density and  bond strength.

Find out more about HVOF here.

How Porsche applied HVOF

Renowned for being the largest manufacture of sports cars in the world, Porsche has recently adopted the method of HVOF to develop what is called the Porsche Surface Coated Brake (PSCB).

To apply the HVOF coating, Porsche started with a standard grey-iron brake rotor, which is the most common form of brake on the market. The surface of the rotor was thermally treated and galvanised, preparing it for the HVOF coating. To create the HVOF coating, Porsche used Tungsten Carbide, which is comparable in durability and hardness to diamond. The surface of the grey-iron brake rotor was coated with about 0.1mm of the Tungsten Carbide. Through the application of this specially developed HVOF coating, Porsche transformed the grey-iron brake rotor to create an entirely new and improved brake system.

The results achieved with HVOF

A first of its kind, the Porsche Surface Coated Brake is nothing less than revolutionary, as it effectively carries more benefits than a standard grey-iron brake, without the expense of carbon ceramic brakes.

By using an HVOF sprayed Tungsten Carbide to coat their brake rotors, Porsche has created a brake system that doesn’t rust, produces less brake dust, is more resistant to brake fade and has better braking response when compared to grey-iron brakes.

Take a look at what Matthias Leber, head of Porsche’s brake division, has to say about HVOF and the new Porsche Surface Coated Brake.

How else HVOF can be used

As demonstrated by Porsche, coatings applied by High Velocity Oxygen Fuel method can be used to significantly increase wear protection. Commonly used in the aerospace and oil & gas industries, HVOF can be applied to pumps, valves, pistons, shafts, drilling tools, bearings and landing gear legs. Able to both provide protection to new components and repair those already damaged, HVOF is a solution designed to improve the performance of operational systems.


Inspired by how Porsche developed and used HVOF coatings?

Contact EP Coatings for more information on HVOF and to find out how it could benefit your business and manufacturing process.