A process for manufacturing a porous abradable coating includes: filling a mold with hollow glass or thermosetting polymer beads and a slurry; and sintering heat treatment to obtain a ceramic layer with pores. A maximum sintering temperature of the green body of the ceramic part is either higher than the melting temperature of the hollow glass beads so that at the end of the sintering heat treatment the hollow glass beads are melted, or higher than the decomposition temperature of the hollow thermosetting polymer beads so that at the end of the sintering heat treatment the hollow thermosetting polymer beads are decomposed.

[Object] This invention, on an assumption that the environmental situation must be considered, reduces the brake noise, prevents the reduction of the braking effectiveness in the high temperature range, and improves the wear resistance.

[Means to Resolve] In the NAO friction material composition that does not practically contain a copper component, this invention contains the first substance made of such as the calcium carbonate that is the substance which becomes the sintered body during braking and is the precursor of the sintered body which keeps the powder generated from the disc rotor, and the second substance made of such as the fluoropolymer that is the sintering additive which aids sintering of the first substance.

[Selected Drawing(s)] None

[Object]

To provide the friction material for the disc brake such as an automobile, which is manufactured by forming the NAO friction material composition, enabling to restrain the brake vibration during braking in a high temperature.

[Means to Resolve]

In the friction material for the disc brake pad, which is manufactured by forming the NAO friction material composition that does not contain the copper component but contains the binder, the fiber base, the organic friction modifier, the inorganic friction modifier, and the lubricant, the friction material composition contains 1-4 weight % of the cashew dust as the organic friction modifier relative to the entire amount of the friction material composition, 7-12 weight % of the muscovite as the inorganic friction modifier relative to the entire friction material composition, and 0.5-5 weight % of the aluminum particle as the inorganic friction modifier relative to the entire amount of the friction material composition.

[Object]

To provide the friction material for the disc brake pad such as an automobile, which is manufactured by forming the NAO friction material composition, enabling to restrain the brake vibration during braking in a high temperature.

[Means to Resolve]

In the friction material, which is manufactured by forming the NAO friction material composition that does not contain the copper component but contains the binder, the fiber base, the organic friction modifier, the inorganic friction modifier, and the lubricant, the friction material composition contains 5-9 weight % of the binder relative to the entire amount of the friction material composition, 1-4 weight % of the silicone rubber modified phenol resin as a part of the binder relative to the entire amount of the friction material composition, 1-4 weight % of a cashew dust as the organic friction modifier relative to the entire amount of the friction material composition, 0.5-3 weight % of a fused silica with the average particle diameter of 15-40 μm as the inorganic friction modifier relative to the entire amount of the friction material composition, and 0.1-2 weight % of the electromelting zirconium silicate beads with the average particle diameter of 10-30 μm as the inorganic friction modifier relative to the entire amount of the friction material composition.

A method includes forming a crystallized metal carbide undercoat on a surface of a carbon-carbon composite substrate. The method further includes forming an overcoat on a surface of the undercoat. The overcoat includes a plurality of crystallized ultra-high melting point overcoat layers. Each overcoat layer is sequentially formed by applying a mixture to a surface of an underlying layer and heating the mixture. The mixture includes a plurality of ultra-high melting point refractory ceramic particles and a pre-ceramic polymer. The mixture is heated to a heat treatment temperature to pyrolyze the pre-ceramic polymer and form the overcoat layer in an inert atmosphere or under vacuum. As a result, the overcoat layer includes a crystallized ultra-high melting point polymer-derived ceramic matrix that includes the plurality of ultra-high melting point refractory ceramic particles.

A method of manufacturing a ceramic matrix composite component may include introducing a gaseous precursor into an inlet portion of a chamber that houses a porous preform and introducing a gaseous mitigation agent into an outlet portion of the chamber that is downstream of the inlet portion of the chamber. The gaseous precursor may include methyltrichlorosilane (MTS) and the gaseous mitigation agent may include hydrogen gas. The introduction of the gaseous precursor may result in densification of the porous preform(s) and the introduction of the gaseous mitigation agent may shift the reaction equilibrium to disfavor the formation of harmful and/or pyrophoric byproduct deposits, which can accumulate in an exhaust conduit 340 of the system.

Method for creating a brake pad with a block of friction material, in which sodium hydroxide and sodium silicate are dissolved in water, the aqueous solution of sodium hydroxide and sodium silicate is mixed with commercial metakaolin until a wet paste is obtained, the wet paste is formed and dried until a dried geopolymeric aggregate is obtained, the aggregate is ground to a powder, the dried ground aggregate is used as an exclusive or almost-exclusive inorganic geopolymeric binder in a friction material compound and the raw compound is hot-molded under a pressure greater than a water saturation pressure at the molding temperature.

An oxidation protection system disposed on a substrate is provided, which may comprise a base layer comprising a first pre-slurry composition comprising a first phosphate glass composition, and/or a sealing layer comprising a second pre-slurry composition comprising a second phosphate glass composition and a strengthening compound comprising boron nitride, a metal oxide, and/or silicon carbide.

The present disclosure provides a method for coating a composite structure, comprising forming a first slurry by combining a first pre-slurry composition comprising a first phosphate glass composition, with a primary flow modifier and a first carrier fluid, wherein the primary flow modifier comprises at least one of cellulose or calcium silicate; applying the first slurry on a surface of the composite structure to form a base layer; and heating the composite structure to a temperature sufficient to adhere the base layer to the composite structure.

The present disclosure provides a method for coating a composite structure, comprising forming a first slurry by combining a first pre-slurry composition with a first carrier fluid, applying the first slurry on a surface of the composite structure, and heating the composite structure to a temperature sufficient to form a base layer on the composite structure. The first pre-slurry composition may comprise a first phosphate glass composition and a low coefficient of thermal expansion material, wherein the low coefficient of thermal expansion material is a material with a coefficient of thermal expansion of less than 10×10.sup.−6° C.