Ceramic-Coated C/C Brake Disk Refurbishment for Longer 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 wear out quickly due to friction and heat, necessitating frequent replacement.
Innovation Solution
A method involving machining to remove existing ceramic coatings from carbon/carbon (C/C) disks, followed by applying new nano ceramic oxide particulate coatings to extend the life of the disks, which can be further combined to form split-disk configurations for additional refurbishment cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If carbon brakes are used for aircraft landing and taxiing, then braking function is achieved, but wear rate increases and service life decreases
Solution Approach 1:
The patent applies a ceramic coating (alumina, zirconia, or silica-based) onto the carbon brake disk surface, creating a composite structure that combines the high-temperature resistance of carbon with the wear resistance of ceramic materials. This composite approach resolves the contradiction by maintaining the braking function while significantly reducing wear rate and extending service life.
Solution Approach 2:
The patent modifies the surface properties of the carbon brake by applying a ceramic coating, changing the surface composition from pure carbon to a ceramic-enhanced composite. This parameter change in surface material composition reduces the wear rate while maintaining the bulk carbon material's thermal management capabilities, thereby extending service life.
2Duration of action of stationary object
If brake disks are refurbished by removing and reapplying ceramic coatings, then material life is extended, but manufacturing complexity increases
Solution Approach 1:
The patent enables refurbishment by removing the worn ceramic coating from carbon brake disks and reapplying fresh ceramic coating material. This process recovers the base carbon disk for renewed service, extending the total service life through multiple refurbishment cycles while managing the complexity through established coating/removal procedures.
Solution Approach 2:
The patent applies ceramic coating to carbon brake disks before they enter service, creating a protective layer that can be removed and reapplied during refurbishment. This preliminary action of coating enables subsequent refurbishment cycles, extending material life while the standardized process keeps manufacturing complexity manageable.
3Reliability
If nano ceramic oxide particulate coatings are applied to carbon disks, then wear resistance increases, but coating application complexity increases
Solution Approach 1:
The patent utilizes porous carbon brake disk surfaces to which nano ceramic oxide particulates (alumina, zirconia, or silica) are applied. The porous structure provides high surface area for coating adhesion, enhancing wear resistance. The coating process, while complex, is managed through controlled application methods that ensure uniform distribution of nano particulates within the porous structure.
Solution Approach 2:
The patent replaces traditional mechanical bonding methods with chemical bonding mechanisms by using sol-gel or plasma-based coating processes that create strong chemical bonds between the nano ceramic oxide particulates and the carbon disk surface. This substitution increases wear resistance while managing application complexity through controlled chemical processes.
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 extends the life of carbon brakes by regenerating ceramic coatings on carbon debris, allowing multiple refurbishment cycles without needing new brake stacks, thus reducing maintenance costs and increasing operational efficiency.
Implementation Method 1
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
Implementation Method 2
coating the wear surfaces of the C/C disk of the second thickness with a second ceramic solution
Implementation Method 3
The second ceramic solution is applied to a wear surface of the C/C disk of the second thickness via at least one of spraying
Implementation Method 4
The second ceramic solution is applied to a wear surface of the C/C disk of the second thickness via at least one of spraying, painting, smearing, brushing, sorption, cold spraying, sputtering
Implementation Method 5
drying the C/C disk of the second thickness coated with the second ceramic solution
Implementation Method 6
The brake systems generally employ a brake stack or heat sink comprising a series of friction disks that may be forced into sliding contact with one another during brake actuation
Implementation Method 7
convert the kinetic energy of the aircraft into heat through frictional forces experienced between the friction disks
Data Source
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.