Segmented Carbon Fiber Preform for Brake Disc Torque
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Solution Overview
Problem
Current manufacturing methods for carbon-carbon composite materials, such as those used in aerospace brake discs, face challenges in optimizing fiber orientation to achieve optimal torque and strength properties, leading to suboptimal performance under high temperature and friction conditions.
Innovation Solution
The method involves creating a fibrous preform with layers of carbon fibers or carbon-precursor fibers, where each layer is divided into inner and outer radial sections with distinct fiber orientation angles, and the layers are needle-punched to form an annulus shape, allowing for tailored fiber orientation to enhance torque and strength properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uniform fiber orientation is used throughout the preform, then manufacturing simplicity is maintained, but torque and strength properties are suboptimal under high temperature and friction conditions
Solution Approach 1:
The preform is divided into multiple layers with different fiber orientation angles. Inner layers have fiber orientations optimized for radial stress resistance, while outer layers have orientations optimized for tangential stress resistance. This local differentiation of fiber properties allows each region to be optimized for its specific stress conditions, thereby improving overall torque and strength properties without requiring complex manufacturing processes.
Solution Approach 2:
The preform structure is segmented into multiple distinct layers, each with independently controlled fiber orientation angles. This segmentation allows the fiber reinforcement pattern to be tailored for different functional requirements at different depths of the brake disc, enabling optimization of mechanical properties while maintaining a relatively simple manufacturing approach through sequential layering.
2Strength
If multi-layer segmented structure with different fiber orientations is implemented, then torque and strength properties are improved, but manufacturing complexity increases
Solution Approach 1:
The fiber orientation angles are predetermined and pre-configured in each layer during preform fabrication. By establishing the optimal fiber orientations in advance during the manufacturing process, the complex mechanical properties are achieved without requiring complex real-time adjustments or post-processing. The preliminary structuring of layers with specific orientations simplifies the overall manufacturing workflow despite the multi-layer complexity.
Data Source
AI summary
A preform for a carbon-carbon composite including a plurality of fibrous layers stacked and needled-punched together to form the preform in the shape of an annulus having an inner radial section and an outer radial section. Each fibrous layer includes a respective plurality of fabric segments comprising at least one of carbon fibers or carbon-precursor fibers. At least one fibrous layer includes a first fabric segment forming at least a portion the inner radial section, the first fabric segment defining a first segment bisector and a first fiber orientation angle, and a second fabric segment forming at least a portion the outer radial section, the second fabric segment defining a second segment bisector and a second fiber orientation angle, where the first and second segment bisectors are radially aligned and the first fiber orientation angle is different than the second fiber orientation angle.