A method of making an assembly having a cast iron subassembly. The method may include providing a steel insert having a first joining surface and bonding the steel insert to a cast iron part to form a cast iron subassembly such that the first joining surface may be an exterior surface of the cast iron subassembly.

A shoe element for use in a drum brake includes a web segment and a support segment, wherein the support segment includes a spherical segment, the web segment includes a web-side engagement segment for interlocking engagement with a shoe web or is integrally formed with a shoe web, and wherein the web segment and the support segment are integrally formed with one another.

A brake disk (1) has a brake disk chamber (2), a friction ring (3) having two friction ring disks (3a, 3b) and a plurality of pin-shaped connecting elements (4) for connecting the brake disk chamber (2) and the friction ring (3). A cooling duct (5) is formed between the fiction ring disks (3a, 3b). The friction ring disks (3a, 3b) have respective friction surfaces (3a1, 3b1) on their outer planar surfaces and respective cooling channel surfaces (3a2, 3b2) on their inner planar surfaces. The friction ring (3) has a plurality of receiving regions (7) for receiving the pin-shaped connecting elements (4). The brake disk chamber (2) is cast to the connecting elements (4) in a separate step by means of casting. A gap (8) existing between the brake disk chamber (2) and the friction ring (3) has such a width (A) which results from the fact that, during casting of the brake disk chamber (2), at least one section (3d) of a lateral surface (3c) of the inner diameter of the friction ring (3) which is closed in itself in the circumferential direction is used as part of a casting mold (9). An axial extension of that part of the receiving area (7) of the friction ring (3) which extends from the cooling channel surface (3a2) in the direction of the cooling channel (5) is 2-10 mm, preferably 4-7.5 mm, even more preferably 5.5 mm.

A brake pad having a layer of friction material integrally moulded with a backing plate, wherein the backing plate having an electroconductive member moulded within a plate of a fibre-reinforced polymer resin, the electroconductive member extending along a plate direction, the backing plate having a front surface forming an interface with a rear surface of the layer of friction material, wherein the electroconductive member is profiled in a thickness direction of the backing plate to provide at least one projection extending towards the interface or into the layer of friction material and arranged to function as a wear indicator for the brake pad. Also disclosed are methods for manufacturing the brake pad.

A method of making a brake caliper housing includes providing a first die and a second die that cooperate to define a cavity when disposed against each other along a mating plane. The method further includes introducing molten material into the cavity to cast the brake caliper housing. One or more surfaces of the brake caliper housing may be machined.

A method for making a braking band (2) for a brake disc (1) for a disc brake, comprising the following steps: a) preparing a mold (10) having an inner cavity (11), which comprises a first portion (11a) of a shape corresponding to the braking band (2) to be made; b) preparing a band preform (20) comprising a central preform (200), an upper outer preform (201) and a lower outer preform (202), said central preform (200) being made of porous ceramic material comprising silicon carbide (SiC), said upper outer preform (201) and lower outer preform (202) being made of porous ceramic material comprising silicon carbide (SiC) and infiltrated with silicon (SiC+Si), wherein a carbon barrier layer (201a, 200a, 200b, 202a) made of carbon is interposed between the upper outer preform (201) and the central preform (200) and between the lower outer preform (202) and the central preform (200), said preforms (200, 201, 202) having the shape of the braking band (2) to be made; c) placing said band preform (20) inside the mold at the first portion (11a) of said inner cavity (11); and d) injecting a liquid or semi-solid aluminum alloy inside the entire inner cavity (11) of the mold (11) to infiltrate the central preform (200) of said band preform (20) made of porous ceramic material with said aluminum alloy, obtaining at the first portion (11a) an aluminum metal matrix composite reinforced by said central preform (200) which defines the braking band (2) to be made. A braking band and a brake disc are made with at least the aforesaid method.

A hysteresis torque generating mechanism includes a first rotor having a slide surface, and a second rotor opposed to the first rotor. The second rotor is configured to slide against the slide surface of the first rotor so as to generate a hysteresis torque. The second rotor includes an initial contact portion and a main friction surface. The initial contact portion is provided to protrude toward the first rotor. The initial contact portion is configured to slide in contact with the slide surface of the first rotor. The main friction surface is configured to slide in contact with the slide surface of the first rotor after abrasion of the initial contact portion.

A method for making a braking band (2) for a brake disc (1) for a disc brake, comprising the following steps: a) preparing a mold (10) having an inner cavity (11), which comprises a first portion (11a) of a shape corresponding to the braking band (2) to be made; b) preparing a band preform (20) comprising a central layer (200) made of porous ceramic material comprising silicon carbide (SiC), an upper outer layer (201) and a lower outer layer (202), said upper outer layer (201) and said lower outer layer (202) being made of porous ceramic material comprising silicon carbide (SiC) and infiltrated with silicon (SiC+Si), said upper outer layer (201) and said bottom outer layer (202) being arranged in an opposing way and on opposite sides of the central layer (200); c) placing said band preform (20) inside the mold at the first portion (11a) of said inner cavity (11); and d) injecting a liquid or semi-solid aluminum alloy inside the entire inner cavity (11) of the mold (11) so as to infiltrate only the central layer (200) of said band preform (20) made of porous ceramic material with said aluminum alloy, obtaining at the first portion (11a) an aluminum metal matrix composite reinforced by said central preform (200) which defines the braking band (2) to be made. A braking band and a brake disc are made at least with the aforesaid method.

The present disclosure relates to a brake disc including a braking part having a circular plate shape having a hollow portion and a plurality of coupling portions protruding and extending from an inner diameter surface thereof, and a hat part disposed in the hollow portion and having a plurality of insertion portions protruding laterally, in which the plurality of coupling portions is respectively coupled to the plurality of insertion portions, and the coupling portion of the braking part and the insertion portion of the hat part are joined to only one of an outboard portion or an inboard portion of the braking part. According to the present disclosure, it is possible to reduce noise occurring at a position at which the hat part and the braking part are coupled to each other and improve cooling performance.

Brake calipers, molds and method of producing brake calipers are disclosed including a brake caliper mold for molding a brake caliper, the brake caliper mold comprising: a first mold section; a second section half; a core member configured to form a piston bore, the core member comprising: a tower configured to form a tower window in a bridge of the brake caliper and a piston bore extension to form a piston bore of the brake caliper; and four locator forming surfaces located on the tower, each of the four locator forming surfaces configured to form a separate lateral data reference surface on the brake caliper, the lateral data reference surfaces capable of being used for subsequent machining of the brake caliper to predetermined tolerances.