Flake graphite cast iron was hot-dip coated with pure aluminium or aluminium alloys (AlSi11 and AlTi5). The study aimed at determining

the influence of bath composition on the thickness, microstructure and phase composition of the coatings. The analysis was conducted by

means of an optical microscope and a scanning electron microscope with an EDS spectrometer. It was found that the overall thickness of a

coating was greatly dependent on the chemical composition of a bath. The coatings consisted of an outer layer and an inner intermetallic

layer, the latter with two zones and dispersed graphite. In all the cases considered, the zone in the inner intermetallic layer adjacent to the

cast iron substrate contained the Al5Fe2 phase with small amount of silicon; the interface between this phase and the cast iron substrate

differed substantially, depending on the bath composition. In the coatings produced by hot-dipping in pure aluminium the zone adjacent to

the outer layer had a composition similar to that produced from an AlTi5 bath, the Al3Fe phase was identified in this zone. The Al3Fe also

contained silicon but its amount was lower than that in the Al5Fe2. In the coatings produced by hot-dipping in AlSi11, the zone adjacent to

the outer layer contained the Al3FeSi phase. The analysis results showed that when AlSi11 alloy was applied, the growth mode of the inner

layer changed from inwards to outwards. The interface between the Al5Fe2 phase and the cast iron substrate was flat and the zone of this

phase was very thin. Locally, there were deep penetrations of the Al5FeSi phase into the outer layer, and the interface between this phase

and the outer layer was irregular. Immersion in an AlTi5 bath caused that the inner intermetallic layer was thicker than when pure

aluminium or AlSi11 alloy baths were used; also, some porosity was observed in this layer; and finally, the interface between the inner

layer and the cast iron substrate was the most irregular.

The paper concerns evaluation of the coefficient of friction characterising a friction couple comprising a commercial brake disc cast of

flake graphite grey iron and a typical brake pad for passenger motor car. For the applied interaction conditions, the brake pressure of

0.53 MPa and the linear velocity measured on the pad-disc trace axis equalling 15 km/h, evolution of the friction coefficient μ values were

observed. It turned out that after a period of 50 minutes, temperature reached the value 270°C and got stabilised. After this time interval,

the friction coefficient value also got stabilised on the level of μ = 0.38. In case of a block in its original state, stabilisation of the friction

coefficient value occurred after a stage in the course of which a continuous growth of its value was observed up to the level μ = 0.41 and

then a decrease to the value μ = 0.38. It can be assumed that occurrence of this stage was an effect of an initial running-in of the friction

couple. In consecutive abrasion tests on the same friction couple, the friction coefficient value stabilisation occurred after the stage of

a steady increase of its value. It can be stated that the stage corresponded to a secondary running-in of the friction couple. The observed

stages lasted for similar periods of time and ended with reaching the stabile level of temperature of the disc-pad contact surface.