A clutch friction material includes a base material containing a rubber material and a thermosetting resin. The clutch friction material also includes an intermediate layer disposed on the base material. The intermediate layer includes either a glassy carbon structure or a graphite structure formed as a result of thermal curing of the thermosetting resin contained in the base material. In addition, the clutch friction material includes an outermost surface layer disposed on the intermediate layer. The outermost surface layer contains a pyrolysate produced as a result of pyrolysis of rubber and resin components contained in the base material.

A friction material presents a friction generating surface and a bonding surface facing opposite the friction generating surface. The friction material includes an organopolysiloxane resin, a plurality of fibers, and a plurality of friction particles. The organopolysiloxane resin includes siloxy units independently represented by the following formula: (R.sub.1SiO.sub.3/2) and/or (R.sub.2SiO.sub.2/2); wherein each R.sub.1 and R.sub.2 is independently selected from a monovalent hydrocarbon group having from 1 to 20 carbon atoms.

A method of making a wet friction material layer includes adding a media in liquid form to a material base including filler particles embedded in a matrix of fibers; drying the media to solidify the media on the filler particles such that the media plugs holes in the filler particles; adding a binder to the material base; and unplugging at least some of the holes in the filler particles by removing at least some of the media from the material base.

A process to manufacture a mixture of p-aramid pulp with chopped fibers, wherein the process includes: providing a first mass that includes p-aramid pulp, providing a second mass that includes chopped fibers, guiding the first mass and the second mass into a mixing device, wherein the first mass and the second mass are mixed to yield a mixed mass, guiding the mixed mass on a dewatering device, whereupon the mixed mass is dewatered to yield a dewatered cake, guiding the dewatered cake, either directly or via a passage, through a cake breaker into a drying atmosphere to yield a dried intermediate, and guiding the dried intermediate, either directly or via a passage, through a homogenizing device into an opening device, wherein the dried intermediate is opened to arrive at an opened mixture of p-aramid pulp and chopped fibers. The mixture and its use are also described.

A friction material comprises a base and a friction generating layer penetrating into and integral with the base. The base presents a bonding surface. The friction generating layer presents a friction generating surface facing opposite the bonding surface of the base. The friction generating layer comprises fibrillated nanofibers, friction adjusting particles, and elastomeric particles. curable resin is dispersed throughout the friction generating layer and the base of the friction material.

The disclosure describes in some examples a technique that includes aligning a plurality of carbon preform segments in a staggered arrangement, where each carbon preform segment of the plurality carbon preform segment includes a carbon body including at least one of a plurality of carbon fibers or a carbon foam, and a silicon-based mixture including silicon particles. The techniques may include heating the staggered arrangement to react the silicon particles with the carbon body to bond the plurality of carbon preform segments together and form a ceramic matrix composite component.

In some examples, the disclosure describes a method including depositing a first layer including a resin and at least one of a carbon fiber or a carbon fiber precursor material on a work surface of a three-dimensional printing system, carbonizing at least the resin of the first layer using a carbonizer attached to the three-dimensional printer to form a first layer of carbon-carbon composite including carbon fibers and carbonized matrix material, depositing an additional layer including a resin and at least one of a carbon fiber or a carbon fiber precursor material of material on the first layer of carbon-carbon composite, and carbonizing at least the resin of the additional layer using the carbonizer to form an additional layer of carbon-carbon composite on the first layer of carbon-carbon composite.

The disclosure describes in some examples a technique that includes aligning a plurality of carbon preform segments in a staggered arrangement, where each carbon preform segment of the plurality carbon preform segment includes a carbon body including at least one of a plurality of carbon fibers or a carbon foam, and a silicon-based mixture including silicon particles. The techniques may include heating the staggered arrangement to react the silicon particles with the carbon body to bond the plurality of carbon preform segments together and form a ceramic matrix composite component.

An example method includes combining an interlayer and a carbon fiber fabric, wherein the interlayer comprises a highly oriented milled carbon fiber ply comprising a plurality of out-of-plane carbon fibers. The method further includes winding the interlayer and the carbon fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform.

In some examples, the disclosure describes a method including depositing a first layer including a resin and at least one of a carbon fiber or a carbon fiber precursor material on a work surface of a three-dimensional printing system, carbonizing at least the resin of the first layer using a carbonizer attached to the three-dimensional printer to form a first layer of carbon-carbon composite including carbon fibers and carbonized matrix material, depositing an additional layer including a resin and at least one of a carbon fiber or a carbon fiber precursor material of material on the first layer of carbon-carbon composite, and carbonizing at least the resin of the additional layer using the carbonizer to form an additional layer of carbon-carbon composite on the first layer of carbon-carbon composite.