A method for manufacturing a ferrous rotational member including the steps of turning a first portion of the friction surface at a sufficient feed rate to provide a first deformed layer on the first portion of the friction surface; fine turning a second portion of the friction surface at a sufficient feed rate to provide a second deformed layer on the second portion of the friction surface; burnishing the first and second portions of the friction surface to achieve a predetermined roughness; and nitrocarburizing the rotational member at a time and temperature sufficient for the diffusion of nitrogen atoms and carbon atoms through the deformed layer to form hardened casings having variable thickness. The ferrous rotational member may be that of a brake rotor having a hub surface and a friction surface, where the hub surface and friction surface have a variable thickness hardened casing.

Systems and methods of making an enhanced brake rotor having enhanced wear resistance are provided. The systems and methods provide a vehicular rotor comprising a base comprising iron (Fe). The base comprises an outer surface having a laser-hardened portion thereon. The laser-hardened portion comprises martensite and having a thickness of between 10 and 100 microns of the outer surface to define the enhanced brake rotor with enhanced wear resistance.

In a method for producing a brake disc, a friction surface layer is sprayed onto the base body or onto an intermediate layer applied on the base body by cold gas spraying a particle mixture which consists 25 to 75% by weight of a metal matrix material and 75 to 25% by weight of a carbide material. The metal matrix material consists of an iron-based alloy, nickel-based alloy, titanium or titanium alloy. The carbide material consists of tungsten carbide, titanium carbide, iron carbide, silicon carbide, chromium carbide or niobium carbide.

A machine assembly includes a first machine component and a second machine component, the first machine component including a first installation surface and the second machine component including a second installation surface. The first and second installation surfaces are mounted against one another in the assembly. A friction-increasing element is provided in the assembly between the first installation surface and the second installation surface. Further, in the assembled state, a sealing material is introduced into an intermediate space between the first and second installation surfaces.

A method for making a braking band of a cast iron brake disc with increased resistance to wear and corrosion, may have the following steps: a) making a braking band of a brake disc of cast iron, preferably gray cast iron; b) immersing at least partially the braking band in molten aluminum maintained at a predetermined temperature so that the molten aluminum covers at least a predetermined surface region of the braking band. Forming intermetallic iron-aluminum compounds at a surface layer of the braking band and generating a layer having of intermetallic iron-aluminum compounds in the predetermined surface region of the braking band. The method may also have the steps of c) extracting the braking band from the molten aluminum; and d) removing the aluminum remaining adherent on the braking band after extraction to expose the layer of intermetallic iron-aluminum compounds on the surface.

In a method for producing a brake disc for a motor vehicle, a base disc, which is made of cast iron or aluminum in particular, is provided and equipped with an anti-corrosion layer. The anti-corrosion layer is applied using a wet chemical or galvanic method.

A brake disc for a disc brake includes a brake disc hub and at least one friction ring which is connected to the brake disc hub via rivets, a jacket of the brake disc hub being provided with sections with a reduced wall thickness and/or apertures which are axially directed material cut-outs situated on the outer circumference of the brake disc hub jacket and serve for at least partial positioning of the axially directed rivets. The friction ring and the brake disc hub are centered with respect to one another exclusively via the rivets, and each rivet, before the deformation thereof, is configured so as to taper conically at least over a part region of the rivet shank thereof in the region of the brake disc hub, starting from a swage head to a rivet closing head.

An internally ventilated brake disk for a disk brake, includes two friction disks, which are arranged adjacent to each other and which are connected to each other by radially extending, regularly arranged webs. The webs extend from an outer peripheral edge to an inner peripheral edge of the friction disks and the friction disks are connected by the webs in such a way that intermediate spaces thereof form cooling channels of equal size, through which cooling air can flow and which are divided by further, shorter webs in such a way that at least one shorter web is located centrally between the webs in a radial region closer to the inner peripheral edge of the friction disks. Outward from the shorter web in the radial direction, the cooling channels are divided into at least three flow channels in that, in each cooling channel, two first further shorter webs are arranged at an offset to each shorter web radially outwardly and in the peripheral direction. The friction disk directed toward a brake disk hub is extended radially inward from each of the shorter webs and is provided with a bore in the axial direction at the height of a collar of the brake disk hub, which bore is used to hold a rivet, which fastens the friction disk to the brake disk hub.

A brake disk for a disk brake, which consists of a brake disk chamber and at least one friction ring connected to the brake disk chamber by rivets, wherein a jacket of the brake disk chamber is provided with sections having reduced wall thickness and/or through-holes, which are axially directed material cut-outs located on the outer periphery of the brake disk chamber jacket, which material cut-outs are used to at least partially place the axially directed rivets. The friction ring and the brake disk chamber are centered with respect to each other exclusively by the rivets. The friction ring has at least one fastening extension directed inward from the friction surface, to which fastening extension a collar of the brake disk chamber jacket is connected by the rivets in that the side of the friction ring directed toward the brake disk chamber has an axially directed depression for accommodating the collar of the brake disk chamber, which depression is designed in such a way that there is radial play between the brake disk chamber and the friction ring.

Systems and methods of making an enhanced brake rotor having enhanced wear resistance are provided. The systems and methods provide a vehicular rotor comprising a base comprising iron (Fe). The base comprises an outer surface having a laser-hardened portion thereon. The laser-hardened portion comprises martensite and having a thickness of between 10 and 100 microns of the outer surface to define the enhanced brake rotor with enhanced wear resistance.