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The Euro 7 Challenge: How Laser Cladding is Revolutionizing Brake Discs to Meet Strict Emission Limits

The New Race to Zero: Euro 7’s Focus on Non-Exhaust Emissions (NEE)

For decades, the automotive industry’s focus on emissions has centered on the tailpipe. However, with the widespread adoption of highly efficient engines and electric vehicles (EVs), attention has decisively shifted to a silent but significant source of air pollution: Non-Exhaust Emissions (NEE), primarily generated by brake and tire wear.
The upcoming Euro 7 standard, slated for phased implementation starting around 2026/2027, is set to fundamentally change brake system design by introducing the world’s first specific limits on brake particulate matter (PM) emissions.

The Quantifiable Challenge of Euro 7 Brake Limits:

The new regulation requires a significant reduction in fine dust pollution. Traditional cast iron brake systems often exceed the 10 mg/km PM limit.

Vehicle Type	Euro 7 Brake PM Limit (PM10)	Starting 2035 (Unified Limit)
ICE & Hybrid Vehicles	7 mg/km	3 mg/km
Pure Electric Vehicles (EVs)	3 mg/km	3 mg/km

This stringent shift means that current material and design practices for brake discs are no longer sufficient. Automotive OEMs and Tier 1 suppliers urgently need a robust, industrial-scale solution that can deliver ultra-low wear, extended service life, and reliable performance.

The Industrial Solution: High-Speed Laser Cladding (LMD)

At Chutian Laser Group, we recognize that this challenge is an opportunity for innovation. Our core solution for Euro 7 compliance is automated brake disc laser cladding line, a sophisticated form of Laser Cladding designed for high-volume, precision hard-coating of brake discs.

What is Laser Cladding for Brake Discs?

Laser Cladding is an advanced surface engineering technique that uses a high-energy laser beam to melt a fine stream of wear-resistant powder—typically Tungsten Carbide (WC) or Titanium Carbide (TiC) mixed in a metallic matrix (e.g., stainless steel).

The process creates a thin, extremely hard coating that is metallurgically bonded to the gray cast iron substrate. Unlike conventional coatings like thermal spraying, this fusion process results in a connection with superior strength (up to 1,000 MPa), ensuring the layer will not peel, chip, or delaminate under extreme braking conditions.

Key Advantages of Chutian Laser Cladding Technology

Our laser cladding solution directly addresses the core pain points introduced by the Euro 7 standard and the accelerating shift to e-mobility:

1. Drastic Particulate Matter Reduction (Euro 7 Compliance)

The super-hard, wear-resistant coating dramatically reduces the friction-induced abrasion between the pad and the disc.
Result: Verified tests demonstrate a reduction in fine dust PM emissions by up to 90%, comfortably meeting the Euro 7’s 7 mg/km and 3 mg/km limits.

2. Extended Lifespan & Sustainability

The hard-coated discs exhibit superior longevity compared to conventional cast iron, significantly reducing the frequency of maintenance and replacement.
Sustainability: Less material consumption and reduced maintenance cycles contribute to a lower total environmental footprint.

3. Unmatched Corrosion Resistance (Essential for EVs)

Electric vehicles primarily use regenerative braking, which reduces the reliance on friction brakes. This often leaves traditional cast iron discs unused and highly susceptible to rust and corrosion.
The laser-cladded coating, often incorporating a corrosion-resistant buffer layer (e.g., stainless steel), provides robust protection against rust, preserving performance and aesthetics—a critical factor for the EV market.

4. Process Efficiency & Quality for Mass Production

HS-LMD Process: Our high-speed laser cladding method minimizes the heat-affected zone (HAZ) on the brake disc, preventing component distortion and maintaining tight tolerances.
Reproducibility: The precision of laser energy input guarantees uniform coating thickness, high hardness, and defined surface roughness for a stable coefficient of friction (CoF), crucial for safety and consistent braking feel.

Why Chutian Laser?

Chutian Laser Group is not just a technology provider; we are an industrial partner ready to scale. Our Laser Cladding solutions are designed for seamless integration into high-volume, automated production lines.

We offer:

Customized Layer Systems: Single or dual-layer coating recipes (stainless steel bonding layer + carbide friction layer) optimized for different vehicle classes and performance requirements.
Proven Reliability: Robust systems engineered for demanding industrial environments and high throughput.