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Reactive sintering to eliminate metal inserts in carbon-carbon brake discs

a technology of carbon-carbon brake discs and insert slots, which is applied in the direction of brake discs, friction linings, mechanical equipment, etc., can solve the problems of carbon-carbon brake disc damage, inserts add significant weight to the brake assembly, and are often too expensive to add to the brake discs

Inactive Publication Date: 2010-02-25
HONEYWELL INT INC +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a method for manufacturing brake discs without the need for inserts or drilling rivet holes. Instead, the invention toughens the face of the carbon-carbon composite material so that it will not crush under pressure. This is achieved by applying a paste made of a carbide-forming metal and carbon powder to the areas where force is applied to the rotor or stator slot faces, which is then heated in a nitrogen atmosphere to create a molten liquid ceramic material on the slot face. The ceramic quickly cools to the temperature of the carbon-carbon composite and the brake disc is then cooled to ambient temperature. The resulting brake disc has a tough, hard, abrasion-resistant ceramic surface on the portion of the brake disc slot that bears pressure. This method simplifies the manufacturing process and improves the performance of brake discs.

Problems solved by technology

However, they are relatively expensive additions to the brake discs.
Damage sometimes occurs to the carbon-carbon brake disc during installation or removal of rivets.
Also, the inserts add significant weight to the brake assembly.

Method used

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  • Reactive sintering to eliminate metal inserts in carbon-carbon brake discs
  • Reactive sintering to eliminate metal inserts in carbon-carbon brake discs

Examples

Experimental program
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Effect test

example 1

[0025]A paste is prepared from 1.0 mol of titanium powder and 0.8 mol of carbon powder in a liquid phenolic binder. This paste is applied in a layer approximately ⅛ inch thick to the faces of slot slots in a carbon-carbon composite brake disc stator. The composite disc having the paste-lined slot slots is placed in a furnace which has a pure nitrogen atmosphere at 1 atmosphere of pressure. Ignition occurs at about 410° C. The maximum combustion temperature reached is 2340° C. The resulting ceramic layer on the faces of the slot slots comprises 0.9 mol TiC and 0.1 mol TiN. This ceramic layer is a refractory material which is stable up to about 3000° C. and which has a Rockwell Hardness, A scale, of about 80 HRA.

example 2

[0026]A paste is prepared from 1.0 mol of zirconium powder and 1.0 mol of carbon powder in a liquid epoxy binder. This paste is applied in a layer approximately 3 / 16 inch thick to the faces of slot slots in a carbon-carbon composite brake disc rotor. The composite disc having the paste-lined slot slots is placed in a furnace which has an air (nitrogen, oxygen, etc.) atmosphere at 0.5 atmospheres of pressure. Ignition occurs at about 600° C. The maximum combustion temperature reached is 2500° C. The resulting ceramic layer on the faces of the slot slots comprises 1.0 mol ZrC and 0.2 mol ZrN. This ceramic layer is a refractory material which is stable up to about 3200° C. and which has a Rockwell Hardness, A scale, of about 95 HRA.

example 3

[0027]A paste is prepared from 1.0 mol of vanadium powder and 0.5 mol of carbon powder in a liquid alginate binder. This paste is applied in a layer approximately 1 / 16 inch thick to the faces of slot slots in a carbon-carbon composite brake disc stator. The composite disc having the paste-lined slot slots is placed in a furnace which contains pressurized nitrogen gas. Ignition occurs at about 410° C. The maximum combustion temperature reached is 2400° C. The resulting ceramic layer on the faces of the slot slots comprises 1.0 mol VC and 0.25 mol VN. This ceramic layer is a refractory material which is stable up to about 3000° C. and which has a Rockwell Hardness, A scale, of about 90 HRA.

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Abstract

A brake disc rotor or stator is manufactured with slots in the interior face of the disc. A paste comprised of a fine powder of a carbide-forming metal along with fine carbon powder, suspended in an organic binder, is applied to the force-bearing areas in the rotor slot faces or the stator slot faces. The disc is then placed into a furnace in a nitrogen atmosphere and heated to the ignition temperature. When the furnace reaches the ignition temperature, a combustion reaction begins that creates a molten liquid ceramic material on the slot face. Upon cooling, the resulting brake disc has a tough, hard, abrasion-resistant ceramic surface on the portion of the brake disc slot that bears pressure.

Description

FIELD OF THE INVENTION[0001]This invention relates to carbon-carbon composite brake discs, and more particularly, to brake disc drive insert slots in carbon-carbon composite brake discs. The present invention provides an improved surface within the brake disc drive insert slots.BACKGROUND OF THE INVENTION[0002]Carbon-carbon composite brake discs used in the aerospace industry typically have metal inserts attached to them. Specifically, the metal inserts are attached to slots in the interior faces of the brake discs (rotors or stators). Those slots function to facilitate the transmission of torque to the brake discs. The metal inserts for stators serve to provide a surface that will transmit torque from the torque tube of the axle to the brake disc without crushing the face of the carbon-carbon composite material. Rotor inserts are used as the media to transmit torque form the wheel drive key interface to the brake discs. The metal inserts—typically held in place by rivets, adhesive,...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): F16D65/12B22F7/04
CPCF16D65/125F16D65/126F16D65/127F16D2200/0039F16D2250/0053F16D69/025
Inventor SIMPSON, ALLEN H.LA FOREST, MARK L.VANDERHEYDEN, GREGORYMUKASYAN, ALEXANDER
Owner HONEYWELL INT INC