The disclosure describes a method of forming a carbon-carbon composite component including depositing an initial carbon material into a porous preform using chemical vapor deposition (CND) or chemical vapor infiltration (CVI) to form a rigidized porous preform, infusing the rigidized porous preform with an isotropic resin, pyrolyzing the infused isotropic resin to form an isotropic carbon within pores of the rigidized porous preform, and encapsulating the isotropic carbon, with a graphitizable carbon to form the carbon-carbon composite component.

In some examples, an article may include a carbon-carbon composite, an antioxidant in pores in a surface of the carbon-carbon composite, and a hydrophobic coating on the surface. The hydrophobic coating includes an oxide of a metal. The metal has a Pauling electronegativity of less than about 1.7. In some examples, the article may be a carbon-carbon composite brake disk that includes a carbon-carbon composite substrate defining a friction surface and a non-friction surface. The antioxidant may be a phosphate-based antioxidant, and the antioxidant may be in pores in the non-friction surface. In some examples, the hydrophobic coating is on the non-friction surface over the phosphate-based antioxidant. In some examples, the hydrophobic coating may include a majority of at least one of yttrium oxide, scandium oxide, or zirconium oxide.

The present application discloses a ceramic preform, a method of making a ceramic preform, a MMC comprising a ceramic preform, and a method of making a MMC. The method of making a ceramic preform generally comprises preparing reinforcing fibers, preparing a ceramic compound, and forming the compound into a desired shape to create the ceramic preform. In certain embodiments, the ceramic compound is formed as either a disc or a ring for use in a brake disc metal matrix composite. The metal matrix composite generally comprises the ceramic preform infiltrated with a molten metal to form the brake disc metal matrix composite. The method of making the metal matrix composite generally comprises heating the ceramic preform, placing the ceramic preform in a mold cavity of a die cast mold, and introducing molten metal into the mold cavity to infiltrate the ceramic preform to form the brake disc metal matrix composite.

A back-plate composition of the present invention is a composition for forming a back plate of a brake pad, the brake pad having a friction material and the back plate bonded to the friction material. The back-plate composition includes a resin, a plurality of first fibers and a plurality of second fibers having an average length shorter than an average length of the first fibers. In the case where the average length of the first fibers is L1 [m] and the average length of the second fibers is L2 [m], L2/L1 is in the range of 0.001 to 0.5. This makes it possible to provide a back-plate composition having excellent moldability, as well as a back plate formed of the back-plate composition, a brake pad including the back-plate and a caliper device provided with the brake pad.

In some examples, a disc brake assembly and methods of forming and assembling said brake disc assembly. The brake disc assembly including a core structure and a plurality of wear pads. The core structure having a first major surface comprising at least one curved ridge or curved channel that extends in a radial direction along the first major surface between an inner and outer diameter of the core structure. Each wear pad defining a friction surface and a mounting surface such that the mounting surfaces of the plurality of wear pads are positioned adjacent to, and in contact with, the first major surface of the core structure, where at least one of the mounting surfaces of the plurality of wear pads includes a corresponding curved ridge or curved channel configured to interlink with the at least one curved ridge or curved channel of the core structure.

A brake backing plate includes first and second sheet metal stampings. Each sheet metal stamping has a respective textured face with a plurality of integrally formed piercing members. A solid non-porous metal core is sandwiched between the first sheet metal stamping and the second sheet metal stamping. The piercing members of the first sheet metal stamping penetrate into the metal core, and the piercing members of the second sheet metal stamping penetrate into the metal core, to secure the first sheet metal stamping, the second sheet metal stamping, and the metal core together.

The invention relates to a method for producing a friction lining material as well as a friction lining material having a porous body, whose pores are filled with a filling material, said porous body being formed on the basis of petroleum coke.

In some examples, a disc brake assembly and methods of forming and assembling said brake disc assembly. The brake disc assembly including a core structure and a plurality of wear pads. The core structure having a first major surface comprising at least one curved ridge or curved channel that extends in a radial direction along the first major surface between an inner and outer diameter of the core structure. Each wear pad defining a friction surface and a mounting surface such that the mounting surfaces of the plurality of wear pads are positioned adjacent to, and in contact with, the first major surface of the core structure, where at least one of the mounting surfaces of the plurality of wear pads includes a corresponding curved ridge or curved channel configured to interlink with the at least one curved ridge or curved channel of the core structure.

A caliper body for a disc brake is described. The caliper body is adapted to straddle an associable brake disc. The caliper body may have a first elongated portion, or a vehicle-side elongated portion, at least partially adapted to face the first braking surface. The caliper bdy may also have a second elongated portion, or wheel-side elongated portion, opposite to the first elongated portion and at least partially adapted to face the second braking surface. At least one part of the first elongated portion has at least a first module and at least one part of the second elongated portion has at least a second module. The first module and the second module are obtained by at least one non-additive manufacturing technique.

A shaped material (1, 1), for example a disk for a disk brake, preferably a ventilated disk, includes a plurality of layers of material (6) in a spiral shape, overlapping along a development axis (X). Each layer of material (6) it is formed by a fabric (2) predominantly or exclusively made of carbon fibres (8), at least part of the layers being impregnated by an impregnating agent. A method is for the manufacture of a shaped material.