Development of a Net Shape Manufacturing Method for Ventilated Brake Discs in Single Piece Design

Abstract

Carbon fibre reinforced ceramic matrix composites (CMC), originally developed for lightweight heat shields of spacecraft, are used for high performance brake discs in sports cars from different manufacturers. In contrast to the CMC materials for space applications, based on woven fabrics and costly manufacturing methods, these low cost friction materials are produced by liquid silicon infiltration of porous Carbon/Carbon (C/C) preforms, based on short fibre reinforced CFRP green bodies manufactured via warm press technique. In this work, different manufacturing methods for ventilated CMC brake discs are compared to each other, and the development of a new technology for the manufacture of single piece C/ C-SiC brake discs in net shape technique is presented.

Coatings for Automotive Gray Cast Iron Brake Discs: A Review

“…Carbon-carbon composites represent yet another class of materials that has been used predominantly for aircraft and motor racing applications, but their inherently high cost and poor braking performance at low temperatures limits their application area [16]. Although not included in Table 1, CMCs such as carbon-fiber reinforced silicon carbide (C/SiC) composites are known to possess excellent thermal stability up to 1300 • C, superior tribological properties over GCI along with significant weight savings but suffer from very high costs and are consequently notably used only in high performance racing cars and luxury vehicles [17][18][19]. Table 1.…”

Low‐Temperature Oxidation Embrittlement of SiC (Nicalon™)/CAS Ceramic Matrix Composites

“…C ontinuous fiber‐reinforced ceramic matrix composites (CMCs) are promising candidates for a number of advanced structural applications, including use in gas turbine engines, automotive brakes, and heat exchangers 1–6 . While there are now several classes of these materials, developed with both dense and porous matrices, the majority of prior work has explored the development and mechanical assessment of materials with compliant interphases between the fiber and matrix.…”