Carbon fiber brakes, particularly carbon-ceramic brakes, are made through a multi-step process involving the creation of a carbon fiber preform, infiltration with silicon, and high-temperature processing.
Here's a breakdown of the general manufacturing process, as suggested by the provided reference (although the reference is brief, and this expands on similar methods):
Steps in Manufacturing Carbon-Ceramic Brakes
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Mixing Carbon Fiber and Resin: This initial stage involves creating a mixture of carbon fibers and a resin, often a phenolic resin. The carbon fibers provide the structural strength, while the resin acts as a binder. The type, length, and orientation of the carbon fibers influence the brake's performance characteristics.
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Molding: The carbon fiber and resin mixture is then placed into a mold that defines the desired shape of the brake disc. Pressure and heat are applied to consolidate the mixture, creating a "molded body" or preform.
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Carbonization: The molded body undergoes carbonization. This process involves heating the molded body to high temperatures in an inert atmosphere (i.e., without oxygen). This causes the resin to decompose, leaving behind a matrix of carbon.
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Silicon Infiltration (Liquid or Gaseous): This is a crucial step that converts the carbon preform into a carbon-ceramic composite. Silicon, in liquid or gaseous form, is infiltrated into the porous carbon matrix. The silicon reacts with the carbon at high temperatures to form silicon carbide (SiC), a very hard and heat-resistant ceramic.
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Final Processing and Finishing: After siliconization, the brake disc undergoes further processing, which may include machining to achieve the final dimensions and surface finish, quality control checks, and application of any protective coatings.
The resulting carbon-ceramic brake discs offer several advantages, including:
- High strength-to-weight ratio: They are significantly lighter than traditional steel brakes, which improves vehicle performance.
- Excellent high-temperature performance: They maintain their braking effectiveness at very high temperatures, making them ideal for racing and high-performance vehicles.
- Resistance to wear: Carbon-ceramic brakes have a long lifespan compared to traditional brakes.
- Reduced brake dust: They produce less brake dust, which contributes to cleaner wheels and reduced environmental impact.
