Ceramic Recoating of Refurbished Carbon Brake Disks for Wear Life
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Solution Overview
Problem
Existing aircraft carbon brakes face challenges in extending the material life of refurbished 2-for-1 carbon brakes, as they experience wear and tear due to friction, necessitating frequent replacement of brake stacks or heat sinks.
Innovation Solution
A method involving machining to remove existing ceramic coatings from carbon/carbon (C/C) disks, followed by application of new nano ceramic oxide particulate coatings to refurbish the disks, which are then paired and coated again to extend their life cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon brakes are used for aircraft landing and stopping, then the brake system can convert kinetic energy to heat through friction, but the friction causes wear and tear on the brake disks necessitating frequent replacement
Solution Approach 1:
The patent applies parameter changes by modifying the surface properties of carbon brake disks through ceramic coating. The ceramic coating changes the friction characteristics and thermal properties of the brake surface, reducing wear rates while maintaining effective braking performance. This allows the brake disks to endure more operational cycles before replacement is needed.
Solution Approach 2:
The patent uses composite materials by combining carbon-based brake disk material with ceramic coating layers. This composite structure leverages the high heat resistance and low friction properties of ceramics while maintaining the structural integrity and braking capability of the carbon substrate, thereby extending service life without compromising reliability.
2Duration of action of moving object
If ceramic coatings are applied to carbon brake disks to reduce wear, then the life of the brakes is extended, but the coating requires periodic removal and reapplication through machining and recoating processes
Solution Approach 1:
The patent applies preliminary action by pre-applying thick ceramic coatings to carbon brake disks during manufacturing or initial refurbishment. These pre-applied coatings are designed to wear down gradually over multiple service cycles, eliminating the need for frequent removal and reapplication. The machining step is performed only when necessary to restore proper disk thickness or surface geometry, not routinely for coating maintenance.
3Reliability
If thick ceramic coatings are applied to carbon brake disks, then wear resistance is improved, but the additional coating thickness increases the overall disk thickness and may affect brake stack geometry
Solution Approach 1:
The patent applies local quality by concentrating the ceramic coating material at the friction surfaces where wear occurs, rather than uniformly thickening the entire disk. The coating is applied selectively to the wear surfaces, providing enhanced wear resistance exactly where needed while maintaining the original disk thickness profile and geometric tolerances critical for brake stack assembly.
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 significantly reduces wear rates and increases the life of carbon brakes by regenerating ceramic coatings on wear debris, allowing for multiple refurbishments without needing new brake stacks, thus enhancing durability and reducing maintenance costs.
Implementation Method 1
The brake stack typically comprises rotor disks and stator disks that, in response to axial compressive loads, convert the kinetic energy of the aircraft into heat through frictional forces experienced between the friction disks
Implementation Method 2
convert the kinetic energy of the aircraft into heat through frictional forces experienced between the friction disks
Data Source
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AI summary
A method is provided for refurbishing a C/C disk of a first thickness and coated with a first ceramic solution for a second life. The method includes machining the C/C disk of the first thickness to remove a coating of the first ceramic solution from the wear surfaces of the C/C disk of the first thickness. Removing the coating of the first ceramic solution further removes a portion of the C/C disk thereby forming a C/C disk of a second thickness. The second thickness is less than the first thickness. The method further includes coating the wear surfaces of the C/C disk of the second thickness with a second ceramic solution, thereby forming a C/C disk of the second thickness coated with the second ceramic solution. Additionally, the method includes drying the C/C disk of the second thickness coated with the second ceramic solution.