A flexible coupling for transmitting torque between parts of a transmission shaft system comprises a tubular section of continuous-fibre-reinforced composite material which has been modified to form a living hinge section with reduced bending stiffness to allow flexion of the tubular section. The tubular section may be modified through the provision of a pattern of formations within the living hinge section. The formations may be in the form of apertures and/or recesses in the continuous-fibre-reinforced composite material to create a plurality of living hinges in the material between, in particular slots and/or grooves.

In some implementations of the current subject matter, a brake rotor can include a supporting layer applied to a friction surface of a brake rotor substrate, which can optionally include cast iron, and a coating applied over the supporting layer. The supporting layer can include a preparatory metal, and the coating can impart wear and corrosion resistant properties to the friction surface. Related systems, methods, articles of manufacture, and the like are disclosed.

A process for manufacturing a friction component made of composite material, includes the densification of a fibrous preform of carbon yarns by a matrix including at least pyrocarbon and at least one ZrO.sub.xC.sub.y phase, where 1≤x≤2 and 0≤y≤1, the matrix being formed by chemical vapor infiltration at least from a first gaseous precursor of pyrocarbon and a second gaseous precursor including zirconium, the second precursor being an alcohol or a C.sub.1 to C.sub.6 polyalcohol modified by linking the oxygen atom of at least one alcohol function to a group of formula —Zr—R.sub.3, the substituents R being identical or different, and R being selected from: —H, C.sub.1 to C.sub.5 carbon chains and halogen atoms.

A method of manufacturing a plurality of wear liner segments may comprise selecting a number of wear liner segments for a wear liner assembly. The wear liner assembly may be annular in shape. The number of wear liner segments may selected based on minimizing a waste portion of a textile board and/or maximizing a production capacity of a plurality of the wear liner assembly.

A flexible coupling for transmitting torque between parts of a transmission shaft system comprises a tubular section of continuous-fibre-reinforced composite material which has been modified to form a living hinge section with reduced bending stiffness to allow flexion of the tubular section. The tubular section may be modified through the provision of a pattern of formations within the living hinge section. The formations may be in the form of apertures and/or recesses in the continuous-fibre-reinforced composite material to create a plurality of living hinges in the material between, in particular slots and/or grooves.

In some implementations of the current subject matter, a brake rotor can include a supporting layer applied to a friction surface of a brake rotor substrate, which can optionally include cast iron, and a coating applied over the supporting layer. The supporting layer can include a preparatory metal, and the coating can impart wear and corrosion resistant properties to the friction surface. Related systems, methods, articles of manufacture, and the like are disclosed.

A method for manufacturing a brake disc includes providing at least one sheet of predefined thickness, blanking a first disc-shaped portion in the at least one sheet adapted to make a first plate of a ventilated braking band, blanking a second disc-shaped portion in the at least one sheet adapted to make a second plate of the ventilated braking band, blanking a third portion in the at least one sheet adapted to make at least one ventilation spacer for the ventilated braking band, drawing the third portion by shaping first and second protrusions, forming opposite first and second recesses adapted to make ventilation channels, connecting the first disc-shaped portion to the first protrusion by discontinuous weld spots, and connecting the second disc-shaped portion to the second protrusion by discontinuous weld spots.

A hybrid torque bar for a brake assembly may comprise a base portion, a pin extending from a first end of the base portion, and a rail extending between the first end of the base portion and a second end of the base portion opposite the first end. The base portion may be formed using a first manufacturing process. At least one of the pin or the rail may be formed using a second manufacturing process. The second manufacturing process may comprise an additive manufacturing technique.

A method is provided for manufacturing an outer ring of a constant velocity joint including an outer ring, an inner rotational member, a torque-transmitting rolling element, and a defining member. The outer ring includes: a first inner peripheral surface to which the defining member is attached; a second inner peripheral surface; and protrusions protruding radially inward of the first inner surface and the second inner peripheral surface so as to restrict axial movement of the inner rotational member and the rolling element. The manufacturing method includes: a plastic working step involving providing a base member; and a bottom removing step involving partially removing a bottom of the base member so as to form a through hole. The plastic working step further involves providing the second inner peripheral surface. The bottom removing step further involves providing the protrusions.

A system includes a rotational coupling including a first rotational joint, a second rotational joint, and a coupling body disposed between the first and second rotational joints. The coupling body includes first and second body portions disposed about a rotational axis, and a layered portion disposed about the rotational axis radially between the first and second body portions. The layered portion includes first and second elastomeric portions disposed about the rotational axis, and a rigid portion disposed about the rotational axis radially between the first and second elastomeric portions. The rigid portion includes a plurality of radial protrusions.