Patent Application
20240229194
This invention relates to a method for making a braking band for a brake disc, a method for making a brake disc, a brake disc, and a braking band for a brake disc made by the aforesaid method.
A brake disc of a disc braking system of a vehicle comprises an annular structure, or braking band, and a central fixing element, known as a bell, by means of which the disc is attached to the rotating part of a vehicle suspension, for example a hub. The braking band is provided with opposing braking surfaces suitable for cooperating with friction elements (brake pads), housed in at least one gripper body placed astride said braking band and integral with a non-rotating component of the vehicle suspension. The controlled interaction between the opposing brake pads and the opposing braking surfaces of the braking band causes a braking action by friction which allows the vehicle to decelerate or stop.
Generally, the brake disc is made of gray cast iron or steel. In fact, these materials allow good braking performance (especially in terms of limiting wear) to be obtained at relatively low cost. Discs made of carbon or carbon-ceramic materials offer much higher performance, but at a much higher cost.
As an alternative to gray cast iron or steel discs, discs made of aluminum have been proposed in order to reduce the weight of the disc. Aluminum discs are equipped with protective coatings. The protective coating serves on the one hand to reduce the wear on the disc and thus ensures performance similar to cast iron discs, and on the other hand to protect the aluminum base from the temperatures generated during braking, which are well above the softening temperatures of aluminum (200-400° C.)
The protective coatings available today and applied to aluminum discs, while offering resistance to wear, are, however, often subject to flaking, which causes said coatings to detach from said disc. This complicates the production process of the disc. In effect, the disc must undergo surface finishing treatments and must also be prepared for connection to the bell.
It is obvious from that which is described above that aluminum or aluminum alloy discs with protective coatings are not currently able to completely replace steel or gray cast iron discs.
However, the lower density of aluminum with respect to both steel and gray cast iron keeps interest in aluminum very high among those in the braking systems industry as an excellent potential substitute for steel and gray cast iron.
In the sector in question, there is therefore a need for aluminum-based brake discs which on the one hand make it possible to exploit the special operational features of aluminum (first and foremost, due to its lower density) and on the other obtain mechanical strength and wear features that are at least comparable to steel or gray cast iron discs. There is also a need to make these discs with production processes that are as simple and economical as possible.
In WO2019/123222A1, a method is described for making aluminum discs with a porous ceramic preform, which is infiltrated with molten aluminum (liquid or semi-solid state). Unfortunately, the disc obtained in this way provides for direct contact between the brake pad and the aluminum-based metal matrix, which generates possible local degradation phenomena on the disc at the points where the aluminum is overheated by friction to its melting point.
There is therefore a strong need in the industry for aluminum-based brake discs that do not degrade locally and that, on the one hand, make it possible to take advantage of the special operational features of aluminum (primarily lower density), and, on the other, obtain mechanical strength and wear features comparable to steel or gray cast iron discs, while at the same time being made with production processes that are as simple and economical as possible.
Together with the aforesaid requirements, there is also the need to have brake discs with greater resistance to corrosion with respect to cast iron or steel discs and with lower emission of polluting metal particles.
The aforesaid requirements are satisfied by a method for making a braking band of a brake disc, a method for making a brake disc, a brake disc for disc brakes, and a braking band according to the appended independent claims.
The method for making the braking band according to this invention comprises the following steps:
Advantageously, for making the band preform, the method comprises the steps of:
As an alternative to step a3), the method advantageously provides the step a4) of depositing the material in particle form comprising carbon to obtain at least one carbon barrier layer made of carbon on the upper outer preform and the lower outer preform.
Further, as an alternative to steps a3) and a4), the method advantageously comprises the step A5) of depositing on the central preform and the upper outer preform and/or the lower outer preform the material in particle form comprising carbon to obtain at least one carbon barrier layer (C) made of carbon on the central preform and the upper outer preform and/or the lower outer preform.
Further, preferably, the method provides for the step a6) of joining the central preform, the upper outer preform, and the lower outer preform together by interposing silicon at each carbon barrier layer and heating said preforms until a junction is formed between them at the carbon barrier layers, obtaining the band preform.
Advantageously, the junction of the central preform with the upper outer preform and with the lower outer preform is formed due to the fusion of the silicon interposed at each carbon barrier layer, which reacts with the carbon deposited in the barrier to form silicon carbide (SiC). The silicon carbide (SiC) thus formed acts as a junction between the preforms.
According to an embodiment, in step a2), the upper outer preform and the lower outer preform are placed in a crucible coated with a release layer, e.g., based on boron nitride (BN), a predetermined amount of silicon (Si) powder is added to the crucible as a function of the size of the preforms, and the upper outer preform and the lower outer preform are heated to obtain the fusion of the added silicon.
Preferably, the upper outer preform and the lower outer preform are heated to a temperature above the melting temperature of Si (1414° C.), at an atmospheric pressure and in inert atmospheres, preferably in an argon atmosphere.
Advantageously, in step a3) or a4) or a5), the step of depositing a material in particle form comprising carbon to obtain at least one carbon barrier layer made of carbon (C) is obtained by chemical vapor deposition.
Preferably, gaseous methane as a carbon precursor is used for chemical vapor deposition; the temperature is from 1100° C. to 1300° C., and the pressure is from 10 to 50 millibars.
Advantageously, the contribution of the gas mixture during the chemical vapor deposition step is:
According to variant embodiments, in step a3) or a4) or a5), the step of depositing a material in particle form comprising carbon to obtain at least one carbon barrier layer made of carbon (C) is obtained by sputtering or the physical vapor deposition (PVD) technique, or with the laser cladding technique.
According to variant embodiments, in step a3) or a4) or a5), the step of depositing a material in particle form comprising carbon to obtain at least one carbon barrier layer made of carbon (C) is achieved by a bonding technique using graphite-based glues.
Preferably, in step a6) the method provides for heating the preforms to a temperature of about 1450° C. for a time of about 2 hours, interposing a stoichiometric amount of silicon depending on the size of the carbon surface of the preform. Preferably, step d) of placing the aluminum alloy inside the mold is conducted according to a semi-solid or liquid infiltration technique or squeeze casting technique.
Advantageously, the central preform, the lower outer preform, and the upper outer preform are obtained by sequentially subjecting a mass of granules made of ceramic material superficially coated with a polymeric binding composition to molding, possibly dewaxing, and sintering.
Preferably, the sintering is conducted in two separate sintering cycles, wherein a first sintering cycle is conducted at a temperature of not less than 1600° C., preferably about 1800° C., and a second sintering cycle is conducted at a temperature of not less than 2000° C., preferably in the range of 2100° C.-2200° C., both in an inert atmosphere.
Further, preferably, in step d), the mold closes over the upper outer preform and the lower outer preform in such a way that, during the injection of aluminum into the mold, the infiltration of aluminum over the upper and lower outer preform is prevented, so that the outer braking surfaces of the braking band are free of aluminum.
The method for making a brake disc comprising a braking band and a bell according to an embodiment of this invention comprises the following steps:
A disc brake according to this invention comprises a braking band and a bell connected to said braking band.
Preferably, in an advantageous way, the bell is connected in one piece with the braking band and is composed of a co-casting made of aluminum alloy with the metal matrix of the composite forming the braking band.
According to this invention, the braking band is composed of a central band made of an aluminum metal matrix composite reinforced by ceramic material comprising silicon carbide (SiC). This composite is obtained by infiltrating a central preform of porous ceramic material having a shape corresponding to the braking band with an aluminum alloy. The braking band is further composed of an upper band and a lower band. The upper band is joined to the central band along an upper junction layer. Said upper band is made of porous ceramic material comprising silicon carbide (SiC) and infiltrated with silicon (SiC+Si) and covers the central band on one of its sides. The lower band is joined to the central band along a lower junction layer arranged opposite, i.e., opposed, to the upper junction layer. The lower band is made of porous ceramic material comprising silicon carbide (SiC) and infiltrated with silicon (SiC+Si) and covers the central band from the other side, i.e., opposed to the upper band.
Preferably, the aluminum alloy matrix has a homogeneously distributed structure within said composite.
Further features and advantages of this invention will become more apparent from the following detailed description of preferred, non-limiting embodiments thereof, wherein:
Elements or parts of elements common to the embodiments described hereinafter will be indicated with the same reference numerals.
With reference to the aforesaid figures, reference numeral 1 globally denotes a brake disc according to this invention.
According to a general embodiment of the invention, illustrated in the accompanying figures, the brake disc 1 comprises a braking band 2, provided with two opposing outer braking surfaces 2a and 2b, each of which at least partially defines one of the two main faces of the disc.
The brake disc 1 further comprises a bell 3, which is connected to the braking band 2.
According to a first aspect of the invention, the braking band 2 is composed of a central band 200′ made of an aluminum-based metal matrix composite reinforced with ceramic material comprising silicon carbide (SiC).
The aforesaid composite falls under the category of composites known in the industry as MMC (metal matrix composite).
The use of said MMC composite comprising aluminum in the braking band 2 allows mechanical and chemical-physical features to be obtained that are even greater with respect to those of aluminum (see in particular density and thus lightness), and at the same time (with respect to a simple fusion in aluminum or its alloy) adds functional features in a heavy application such as that required in a braking system without needing protective coatings on the braking surfaces.
Further, the braking band 2 is also composed of an upper band 201′ that is joined to the central band 200′ along an upper junction layer 22a. The upper band 201′ is made of porous ceramic material comprising silicon carbide (SiC) and infiltrated with silicon (SiC+Si). Further, the upper band 201′ covers the central band 200′ on one side thereof, so that on said side, the central band 200′ is not subjected to contact with the brake pads when the brake disc is mounted on the disc brake.
Additionally, the braking band 2 is composed of a lower band 202′ that is joined to the central band 200′ along a lower junction layer 22b arranged opposite, i.e., opposed, to the upper central layer 201′. The lower band 202′ is also made of porous ceramic material comprising silicon carbide (SiC) and infiltrated with silicon (SiC+Si). Further, the lower band 202′ covers the central band 200′ on the other side, i.e., opposite to the upper band 201′. In this way, the result is that the central band 200′ is sandwiched between the upper band 201′ and the lower band 202′. In particular, the outer braking surfaces 2a, 2b of the braking band 2 are each outermost surfaces of the lower band 202′ and the upper band 201′ which are not joined to the central band 200′.
With respect to a braking band made only with aluminum or one of the alloys thereof, the presence of the reinforcement made of ceramic material in the central band 200′ and the presence of the upper band 201′ and the lower band 202 allow greater hardness, greater rigidity, a higher friction coefficient, and higher wear resistance to be obtained. All these features make this braking band suitable for use for a brake disc.
In this way it is possible to create a braking band with the advantageous features of aluminum (see in particular the lower density with respect to steel and cast iron), but at the same time avoiding the need to provide the braking surfaces with protective coatings, and the limitations and inconveniences thereof, both productive and operational.
The aforesaid ceramic material from which the reinforcement is made is silicon carbide.
As will be taken up later in the description, the MMC composite forming the central band 200′ is obtained by infiltrating a porous ceramic material preform with an aluminum alloy. Advantageously, the ceramic materials listed above, including silicon carbide, are able to withstand the step of infiltrating by the molten metal without altering their chemical and physical structure and without being damaged macroscopically and microscopically to any extent. For this reason, too, they are particularly suitable for making the aforesaid composite.
Preferably, the aluminum alloy is chosen from the group composed of alloys suitable for fusion processes, preferably containing at least silicon, at least manganese, at least magnesium.
An advantageous embodiment provides that the aluminum alloy has a high magnesium (Mg) content, more preferably with high magnesium and silicon (Si) content.
Preferably, the magnesium (Mg) content is less than 15%, even more preferably less than 10% but at least 0.2%. This provides increased mechanical properties and machinability on machine tools, as well as ensuring increased corrosion resistance and an improved ability of the alloy to fill complex mold shapes by lowering the surface tension of the alloy in the liquid state. Preferably, the aluminum alloy is AlSi13Mg9Ti alloy.
Advantageously, the aluminum alloy matrix has a homogeneously distributed structure within the composite. As will be discussed below, this may be achieved by infiltrating with aluminum alloy a preform made of porous ceramic material having a homogeneous porosity throughout its volume. The aluminum alloy—due to the infiltration process—permeates the porosity of the ceramic material creating a homogeneous structure.
According to another aspect of this invention, the brake disc 1 provides for the aforesaid bell 3 to be connected in one piece with the braking band 2 and is composed of an aluminum alloy co-casting with the metal matrix of the composite forming the braking band 2.
As will be taken up hereinafter in the description, in this variant the bell 3 is obtained in the same mold wherein the infiltration with aluminum alloy of the preform in ceramic material is carried out, using the same aluminum alloy. In this way, in the same operating step, the forming of the composite material and the fusion of the bell are obtained, achieving a complete joint of the two materials.
Making the bell in co-casting with the braking band allows for the production process to be significantly simplified. In fact, it avoids the need to set up both a dedicated production line to produce the bell and an assembly line for assembling the bell on the band.
The combination of the aforesaid two essential aspects of the invention makes it possible to have aluminum-based brake discs that make it possible on the one hand to exploit the special operational features deriving from aluminum (first and foremost the lower density) and on the other hand to have mechanical and wear resistance features comparable to steel or gray cast iron discs, and at the same time may be made with production processes that are as simple and economical as possible.
It is obvious that, according to an embodiment, the braking band 2 according to this invention is also connectable with a bell 3 which is not co-fused (or made in one piece) but is connected through bell-band connection means according to the prior art (assembly, interference fitting, riveting, and the like).
In other words, once only the braking band 2 has been made, it is suitable to be assembled with the bell 3 in the known manner for making a brake disc, thus obtaining a brake disc, for example, by floating compound or interference fitting.
Therefore, it is understood that in this discussion, the intention is also to protect a method of making the brake disc comprising also a final step of the method wherein there is provided a connection between the braking band 2 according to this invention and the bell 3 not in one co-fused piece but through bell-band connection means, for example by assembly, interference fitting, riveting, and the like.
For simplicity of discussion, the braking band 2 and the brake disc 1 will now be described contextually with their respective methods of fabrication according to this invention. The brake disc 1 is preferably, but not necessarily, made with the method according to the invention which will now be described.
According to a general embodiment of the method according to the invention, the method for making the brake disc 1 comprises a first operating step a) for preparing a mold 10 having an inner cavity 11 comprising a first portion 11a of a shape corresponding to the braking band 2 of the brake disc 1 to be made and a second portion 11b of a shape corresponding to the bell 3 of the brake disc 1 to be made.
The first portion 11a and the second portion 11b of said inner cavity 11 communicate with each other, as illustrated in
Advantageously, as illustrated in
The method comprises a second operating step b) of 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 is made of porous ceramic material comprising silicon carbide (SiC). Further, the upper outer preform 201 and the lower outer preform 202 are made of porous ceramic material comprising silicon carbide (SiC) and infiltrated with silicon (SiC+Si). 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.
Advantageously, said carbon barrier layer 201a, 200a, 200b, 202a made of carbon allows for making the joint between the preforms 200, 201, 202 more stable and reliable and to act as an auxiliary barrier layer in the step of infiltrating aluminum into the central preform 200, so as to further limit the possibility of aluminum infiltrating the upper outer preform 201 and the lower outer preform 202. The aforesaid preforms 200, 201, 202 have a shape substantially the same as the shape of the braking band 2 of the brake disc 1 to be made.
The method further comprises the following additional operating steps:
The injection of the aluminum alloy is conducted so as to infiltrate with the aforesaid aluminum alloy the central preform 200 of said band preform 20, obtaining in the first portion 11a an aluminum-based metal matrix composite reinforced by the central preform 200 which partially defines the braking band 2 of the brake disc to be made, and in such a way as to fill the second portion 11b with the aforesaid aluminum alloy, obtaining an aluminum alloy fusion which is connected in one piece with the braking band 2 made of metal matrix composite, and defines the bell 3 of the brake disc 1 to be made.
According to a general embodiment, the method for making a braking band 2 for a brake disc 1 comprises a sequence of steps similar to the steps of the method for making the brake disc, except for the fact that the mold 10 is shaped for making only the braking band 2 and not for making the bell 3. Consequently, with respect to the steps of the method for making the brake disc, in step a) the mold does not comprise a second portion 11b of a shape corresponding to the bell 3 of the brake disc 1 to be made. Further, with respect to the method for making the brake disc 1, in step d), the infiltration of the aluminum alloy is conducted only so as to infiltrate the central preform 200 of said band preform 20 with the aforesaid aluminum alloy, obtaining in the first portion 11a an aluminum-based metal matrix composite reinforced by the central preform 200 that partially defines the braking band 2 of the brake disc to be made. It is apparent that, for making the braking band only, it is not necessary to provide for the aluminum alloy to fill the second portion 11b, since the simultaneous production of the bell of the brake disc 2 by co-casting is not required. Although the mold for the method for making the braking band is not depicted in the appended figures, how to modify the aforesaid mold 10 so that it is free of the second portion 11b intended for making the bell may be clearly and unequivocally derived by a person skilled in the art.
Thus, in a general embodiment, the method for making the braking band according to this invention comprises a first operating step a) of preparing a mold 10 having an inner cavity 11 comprising a first portion 11a of a shape corresponding to the braking band 2 of the brake disc 1 to be made.
Also in this case, the mold comprises one or more inlet openings 13 for injecting the aluminum alloy directly into the second portion of the inner cavity 11 of the mold 10.
The method comprises a second operating step b) of 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 is made of porous ceramic material comprising silicon carbide (SiC). In addition, the upper outer preform 201 and the lower outer preform 202 are made of porous ceramic material comprising silicon carbide (SiC) and infiltrated with silicon (SiC+Si). 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 have a shape substantially the same as the shape of the braking band 2 of the brake disc 1 to be made.
The method further comprises the following additional operating steps:
The injection of the aluminum alloy is conducted so as to infiltrate with the aforesaid aluminum alloy the central preform 200 of said band preform 20, obtaining at the first portion 11a an aluminum metal matrix composite reinforced by the central preform 200 that partially defines the braking band 2 of the brake disc to be made.
Advantageously, for producing the brake disc 1 as well as for producing the braking band 2, step b) of injecting the aluminum alloy within the mold may be conducted following any technique fit for the purpose.
In particular, step b) may be conducted according to a liquid-state infiltration technique, according to a squeeze casting technique, according to a gravity infiltration technique, or according to a semi-solid-state infiltration technique, or by die casting with liquid aluminum.
In the case of gravity infiltration, the infiltration preferably takes place in an inert atmosphere, such as a nitrogen atmosphere.
The aforesaid infiltration techniques are well known to a person skilled in the art and will therefore not be described here.
Preferably, step b) of injecting the aluminum alloy inside the mold is conducted according to a semi-solid infiltration technique. In fact, it has been found that this technique is more suitable for infiltrating ceramic preforms so that at the end of the process the resulting disc made of MMC material has homogeneous features throughout its structure. At the same time, this technique is suitable for forming the bell within the same process.
More specifically, infiltration at the semi-solid stage occurs at a temperature between the liquidus and solidus line of the aluminum alloy used, i.e., with the alloy in a semi-solid state. Due to the low viscosity of the semi-solid mass, the process of injection into the mold and infiltration occurs smoothly and with low turbulence.
That which is particularly advantageous is that the presence of the upper outer band and the lower outer band, infiltrated with silicon, prevents aluminum from infiltrating said upper and lower outer bands. The result is a pair of opposing braking surfaces 2a, 2b that are particularly suitable for use in a brake disc, as they are free of aluminum and have improved friction coefficients with respect to the prior art for aluminum discs. In addition, the further presence of the carbon barrier layer ensures even more advantageously that aluminum migration from the central preform to the upper and lower outer preforms does not occur during the aluminum infiltration step.
According to a preferred embodiment of the method for making the braking band 2 or the method for making the brake disc 1, the aforesaid band preform 20 made of porous ceramic material is obtained by subjecting a mass of ceramic material granules, superficially coated with a polymeric binding composition, to the following sequential operating steps: molding, debonding (or dewaxing), and sintering.
Advantageously, the aforesaid ceramic material granules are powder granules known as “ready-to-press.” This kind of commercially available powder allows “net shape molded” products to be obtained, without the need of other components or additives besides said powder.
Preferably, the aforesaid ceramic material from which the granules are formed is silicon carbide.
Preferably, the polymeric binding composition that coats the ceramic material granules is chosen from the group consisting of thermoplastic and thermosetting polymers.
Preferably, the molding of the mass of ceramic material granules is done uniaxially or isostatically or using any other technique that allows for a preform of such a size and shape to be obtained.
At the end of the molding process, an aggregate of the aforesaid ceramic material granules is obtained, connected by ceramic microstructures facilitated by the respective coatings of polymeric binding composition. Said aggregate contains organic residues from the granule coatings. These organic residues are removed in the debonding (or dewaxing) step.
Advantageously, debonding is conducted under air flow conditions at a temperature below 700° C. until the organic phase present in the mass of ceramic material granules after molding is fully eliminated.
According to a variant, debonding is conducted under inert atmospheric conditions.
At the end of the debonding step, a green body is obtained, consisting essentially only of ceramic material. This green body is then subjected to the sintering phase that transforms the green body into a continuous structure obtained by the formation of bridges connecting the individual ceramic particles. This results in a body that exhibits homogeneous properties throughout the structure.
Preferably, the sintering is conducted in two separate sintering cycles. A first sintering cycle is conducted at a temperature of not less than 1600° C., preferably about 1800° C., and a second sintering cycle is conducted at a temperature of not less than 2000° C., preferably in the range of 2100° C.-2200° C., both under an inert atmosphere.
Advantageously, the resulting band preform 20 made of porous ceramic material has a homogeneous distribution of density and porosity throughout its volume. Said features make the preform suitable for making a homogeneously distributed aluminum alloy matrix following its infiltration with said alloy.
According to an advantageous embodiment, both the method for making the braking band and the method for making the brake disc comprise a sequence of operating steps to be executed before step b), for example illustrated schematically in
Additionally, the aforesaid sequence of operating steps provides for a subsequent operating step a2) of infiltrating the upper outer preform 201 and the lower outer preform 202 with silicon (Si). Infiltration with silicon prevents there being space for the aluminum to infiltrate the preform in the infiltration step of the aluminum alloy.
Preferably, in this step a2) the upper outer preform 201 and the lower outer preform 202 are placed in a crucible coated with a release layer, for example based on boron nitride (BN), and a predetermined amount of silicon (Si) powder is added to the crucible. Subsequently, the upper outer preform 201 and the lower outer preform 202 are heated to achieve the fusion of the added silicon and, thus, infiltration.
Advantageously, the upper outer preform 201 and the lower outer preform 202 are heated to a temperature above the melting temperature of Si (1414° C.), at an atmospheric pressure and in inert atmospheres, preferably in an argon atmosphere. The process may be accomplished using appropriately sized industrial furnaces.
According to a variant, the upper outer preform 201 and/or the lower outer preform 202 are heated to a temperature above the melting temperature of Si (1414° C.) at a pressure other than atmospheric pressure, for example even in a controlled vacuum.
Additionally, preferably, following the infiltration process, the upper and lower outer preforms are optionally leveled (ground) before being subjected to the subsequent steps described below.
The aforesaid sequence of operating steps provides for a further operating step a3) of depositing on the central preform 200 a material in particle form comprising carbon to obtain at least one carbon barrier layer 200a, 200b made of carbon, as for example shown in
As an alternative to step a3), a step a4) may be provided to deposit on the upper outer preform 201 and lower outer preform 202 a material in particle form comprising carbon to provide at least one carbon barrier layer 201a, 202a made of carbon (C) on each of the upper outer preform 201 and lower outer preform 202, as for example shown in
Additionally, as an alternative to steps a3) and a4), a step a5) may be provided to deposit on the central preform 200 and upper outer preform 201 and/or lower outer preform 202 a material in particle form comprising carbon to achieve at least one carbon barrier layer 200a and/or 200b, 201a and/or 202a made of carbon (C) on the central preform 200 and upper outer preform 201 and/or lower outer preform 202, as for example shown in
In other words, preferably in any variant of the method described herein, a carbon barrier layer may be created between the upper outer preform 201 and the central preform 200 and between the lower outer preform 202 and the central preform 200, either by providing for a deposition exclusively on the upper and lower outer preforms, or by providing for a deposition exclusively on two opposing faces 2000, 2001 of the central preform, or by providing for a deposition on both the central preform 200 and the upper outer preform 201 and lower outer preform 202.
It is obvious that, preferably, the carbon barrier layer (and thus its deposition) is created only on one of the two opposing faces 2010, 2011; 2020, 2021 of each of the upper and lower outer preforms.
It is also obvious that, preferably, the central preform 200, the upper outer preform 201, and the lower outer preform 202 have an annular disc shape, preferably with a central through hole 5. Preferably, the two opposing faces 2000, 2001; 2010, 2011; 2020, 2021 are the two opposing faces of the disc shape having the greatest extension.
The two opposing faces 2000, 2001; 2010, 2011; 2020, 2021 of each preform, therefore, comprise an upper face 2000; 2010; 2020 and an opposing lower face 2001; 2011; 2021, joined together by a side wall 2002; 2012; 2022 that develops incidentally, preferably perpendicularly, to the upper faces 2000; 2010; 2020 and lower faces 2001; 2011; 2021, i.e., forming the shell of the disc.
Preferably, in the case wherein each preform is already provided with a central through-hole 5, it is obvious that said preform will thus also have an inner side wall 2003; 2013; 2023, opposing the side wall 2002; 2012; 2022.
The aforesaid sequence of operating steps provides for a further subsequent operating step a6) of joining together the central preform 200, the upper outer preform 201, and the lower outer preform 202 by interposing silicon (Si) at each carbon barrier layer 200a and/or 200b, 201a and/or 202a and heating said preforms 200, 201, 202 until a joint is formed between them at the carbon barrier layers 200a and/or 200b, 201a and/or 202a, thereby obtaining the band preform 20. Preferably, therefore, silicon (Si), e.g., solid silicon, is interposed between each carbon barrier layer 200a and/or 200b, and the upper outer preform 201 and the lower outer preform 202, or between each carbon barrier layer 201a and/or 202a and the central preform 200, or between each carbon barrier layer 200a and/or 200b and the corresponding facing carbon barrier layer 201a and/or 202a.
Advantageously, said step a6) of creating the junction between the central preform 200 and the upper outer preform 201 and lower outer preform 202 provides for heating the preforms 200, 201, 202 to a temperature of about 1450° C. for a time of about 2 hours by interposing a stoichiometric amount of silicon between the preforms as a function of the size of said preforms.
For example, the stoichiometric amount of silicon (MSi) may be calculated as follows. Once the total volume of carbon is defined:
VC=π(R2−r2)h,
where the radii R and r are the outer radius R and inner radius r, respectively, of the circular crown described by the preform 200, 201, or 202, and h is the thickness of the carbon barrier layer (assuming the layer is compact and free of porosity); it is possible to calculate the mass of carbon C deposited as
MC=VC×Dc,
where Dc is the carbon density.
Given the formula Si+C=SiC, knowing that 1 mole of silicon (Si) reacts with 1 mole of carbon (C) to generate one mole of silicon carbide (SiC), and the atomic weights of the components being known, it is possible to calculate stoichiometric amounts of silicon as:
MSi=MC×atomic weight Si/atomic weight C.
For example, in the case where the preforms have a diameter of about 40 millimeters and the amount of Si needed is about 3 grams, said parameters allow an adequate and reliable junction between the preforms to be obtained.
It is obvious that, depending on the process adopted, once the minimum stoichiometric quantity of Si (MSi) necessary to react with carbon C according to the aforesaid formulas is known, it is possible to optionally proceed by increasing the amount of silicon in order to bring in more or less hyperstoichiometric conditions in order to ensure the completion of the chemical reaction.
Obviously, once the band preform 20 is obtained as described above, the central preform 200 corresponds to the central band 200′ of the braking band 20, and the upper outer band 201 and lower outer band 202 correspond to the upper outer band 201′ and lower outer band 202′ of the braking band 20, respectively.
According to a preferred embodiment, in step a3) or a4) or a5), the step of depositing a material in particle form comprising carbon to obtain at least one carbon barrier layer 200a, 200b, 201a, 202a made of carbon (C) is achieved by chemical vapor deposition.
Preferably, gaseous methane as a carbon precursor is used for chemical vapor deposition, the temperature is 1100° C. to 1300° C., and the pressure is 10 to 50 millibars.
Even more preferably, the contribution of the gas mixture during the chemical vapor deposition step is:
The aforesaid parameters allow for a carbon barrier layer, that is a carbon coating, to be obtained on the preforms, minimizing as much as possible the risk of infiltration in said preforms.
Advantageously, in step d) of the method according to this invention, as visible, for example, in
According to a variant of the method, appreciable more clearly in
Preferably, in this step a11) protection of one or more regions of the upper outer preform 201, the lower outer preform 202, and the central preform 200 is achieved by placing the aforesaid preforms 200, 201, 202 in a crucible coated with a release layer, for example based on boron nitride (BN), where necessary.
Preferably, the release layer 200″, 201″, and 202″ is positioned in the vicinity of the side wall 2002; 2012; 2022 of the central preform 200 and/or the upper outer preform 201 and/or the lower outer preform 202, so as to prevent infiltration of silicon in the radial R direction, through the disc.
In this variant, after step a6), i.e., after the junction between the preforms 200, 201, 202 has been formed at the carbon barrier layers 200a and/or 200b, 201a and/or 202a, to obtain the preform the band preform 20, the method comprises executing the following steps:
It is obvious that the main difference in this variant of the method lies in executing the silicon infiltration step in the upper outer preform 201 and the lower outer preform 202, after executing the mechanical junction between the lower outer preform and the central preform and between the upper outer preform and the central preform, along the carbon barrier layer.
Therefore, the additional steps, e.g., steps a3), a4) or a5) and all other steps and details of the steps of the method described above, are understood to be equally valid and applicable to this variant of the method, as moreover clearly illustrated in
According to an embodiment of the aforesaid variant of the method, in particular shown in
In particular, for example, the method provides for masking at least partially or completely the upper face 2010; 2020 and/or the opposing lower face 2011; 2021, of the upper outer preform 201 and/or the lower outer preform 202.
As may be appreciated from that which has been described, the braking band, the brake disc and the methods for making said brake disc and said braking band according to the invention make it possible to overcome the drawbacks presented in the prior art.
In a particularly innovative manner, in fact, the braking band and brake disc of this invention, by interposing two outer braking bands made of ceramic composite material between the brake pads and the central band made of composite material with an aluminum alloy metal matrix, allows the problems related to local degradation due to overheating of the aluminum, found in the prior art, to be reduced—if not eliminated. In addition, they allow for the simultaneous development of greater braking force, due to the coupling of the pads on a material with a higher friction coefficient. At the same time, efficiency, simplicity, low implementation cost and reduced corrosion problems are ensured. Reduced corrosion is particularly advantageous in electric vehicles, where the introduction of regenerative braking involves discontinuous use of the disc brake, which may lead to corrosive phenomena.
A person skilled in the art, for the purpose of meeting contingent and specific needs, may make numerous modifications and variants to the disc and disc brake described above, all of which, however, are contained within the scope of the invention as defined by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102021000004454 | Feb 2021 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2022/051546 | 2/22/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 20240132999 A1 | Apr 2024 | US |
