Brake Caliper Insert Porosity and Metal Infiltration
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Solution Overview
Problem
Current methods for implementing inserts with structural functions in braking systems, particularly in calipers, face challenges in achieving a strong bond between the insert and the metal matrix, leading to brittleness and structural discontinuities, which complicates processing and thermal treatments, and results in bulky, heavy caliper bodies that compromise braking performance.
Innovation Solution
A method involving a ceramic or metal-ceramic composite insert with a porous structure, where a binder material is used to create porosities that allow for infiltration of a metal matrix, ensuring a strong and stable bond while maintaining the structural integrity of the insert, allowing for efficient stress transfer and reduced caliper weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallurgic bonding techniques are used to bond inserts to metal matrix, then bonding strength is improved, but brittleness areas are created that cause structural discontinuity
Solution Approach 1:
An intermediate bonding layer comprising aluminum and ceramic particles is introduced between the metal matrix and the ceramic insert. This intermediate layer acts as a mediator that provides metallurgic bonding to the metal matrix while avoiding the formation of brittle intermetallic phases, thus maintaining structural continuity and reliability.
Solution Approach 2:
The bonding interface is designed as a composite material structure with multiple layers: a first layer of aluminum alloy for metallurgic bonding to the metal matrix, and a second layer of ceramic material for bonding to the ceramic insert. This composite structure eliminates brittle areas while ensuring strong bonding on both sides.
2Weight of moving object
If ceramic inserts are used to reduce weight, then weight reduction is achieved, but bonding difficulties arise due to non-wettability by metals
Solution Approach 1:
An intermediate bonding layer comprising aluminum and ceramic particles is introduced between the metal matrix and the ceramic insert. This intermediate layer acts as a mediator that provides metallurgic bonding to the metal matrix while avoiding the formation of brittle intermetallic phases, thus maintaining structural continuity and reliability.
Solution Approach 2:
The bonding interface is designed as a composite material structure with multiple layers: a first layer of aluminum alloy for metallurgic bonding to the metal matrix, and a second layer of ceramic material for bonding to the ceramic insert. This composite structure eliminates brittle areas while ensuring strong bonding on both sides.
3Stability of the object's composition
If large dimensional caliper bodies are used to prevent deformation, then structural stability is improved, but weight and bulk increase
Solution Approach 1:
The caliper body is designed as a composite structure combining metal matrix (aluminum alloy) and ceramic inserts (alumina or silicon carbide). The ceramic inserts provide high stiffness and strength to prevent deformation under braking loads, while the aluminum matrix keeps the overall weight low. This composite approach allows using smaller, lighter caliper dimensions while maintaining structural stability.
Solution Approach 2:
Ceramic inserts with high structural performance are strategically positioned in specific regions of the caliper body where stress concentrations occur or where additional stiffness is needed. This local reinforcement approach maintains structural stability without requiring the entire caliper body to be oversized, thus avoiding unnecessary weight increase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves a robust and lightweight caliper body with improved mechanical performance, enabling effective stress transfer and enhanced braking action without deformation, while reducing the caliper's weight and dimensions, and providing resistance to high temperatures and oxidative phenomena.
Implementation Method 1
a binder material which, by volatilizing before or as the material of the insert is sintered, determines where the porosity was
Implementation Method 2
the material of which is infiltrated in the porosity of the insert
Data Source
Figure 1~4
Figure 5a~7
Figure 5b~6d
AI summary
The present invention relates to a method and a brake component surprisingly capable of high structural performance, in which a first granular material (2) adapted to the sinterization is provided, which is capable of high structural performance; a second binder material (3) constituting a volumetric filler is provided, which is capable of partially separating the granules of the first sinterization granular material (2) one from the other; a predefined amount of the first sinterization granular material adapted to constitute the core of an insert (4) is placed in a mold (5; 14); the first sinterization material (2) is mixed in pre-established parts to the second volumetric filling material (3); the mixture (6) of the first and second materials is placed in a mold (7; 14) for said insert (4); the first sinterization material is constipated with a predefined pressure; the mixture of the first and second materials is constipated with a predefined pressure; the second volumetric filling material is volatilized, while the sinterization of the first material starts, thus generating porosities (8) where the second material was; the sinterization of the first material is carried on, thus forming an insert (4); said insert (4) is introduced into a die (9) for the implementation of the braking system component; a third material (10) is injected into said die (9) at a pre-established temperature and pressure to form the body (11 ) of the braking system component, embedding said insert (4) in the body so that the third material (10) infiltrates in said porosities (8) of the insert (4), thus firmly anchoring said insert (4) to said body (11 ), without noticeably altering the properties of the sinterized material (2).