C/C Friction Disk Coating for Oxidation and Wear Protection

The protective coating system is divided into multiple functional layers: a first coating containing boron carbide powder applied to non-wear surfaces for oxidation protection, and a second coating containing aluminum and silicon applied to wear surfaces for wear resistance. Each layer serves a specific protective function, allowing the system to achieve comprehensive protection while maintaining manageable manufacturing complexity through functional segmentation.

The patent employs composite coating materials combining different substances with complementary properties. The first coating uses boron carbide powder known for its oxidation resistance, while the second coating uses aluminum and silicon compounds for wear protection. These composite material combinations enable the C/C friction disk to simultaneously achieve both oxidation resistance and wear durability without requiring a single complex material.

The coating components are prepared as pre-formulated mixtures containing the necessary powders, surfactants, and carrier fluids before application. The first coating mixture is prepared with boron carbide powder and applied to non-wear surfaces, followed by the second coating mixture with aluminum and silicon applied to wear surfaces. This preliminary preparation of coating mixtures streamlines the manufacturing process and reduces overall production time.

The patent specifies controlled thickness parameters for each coating layer (0.0002 to 0.003 inches) and uses carrier fluids that facilitate uniform application and controlled drying. By optimizing these parameters, the multi-layer coating process achieves efficient production with reduced processing time while maintaining the required protective performance.