WO2008093078A1 - Améliorations concernant les disques de frein et d'embrayage - Google Patents

Améliorations concernant les disques de frein et d'embrayage Download PDF

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Publication number
WO2008093078A1
WO2008093078A1 PCT/GB2008/000308 GB2008000308W WO2008093078A1 WO 2008093078 A1 WO2008093078 A1 WO 2008093078A1 GB 2008000308 W GB2008000308 W GB 2008000308W WO 2008093078 A1 WO2008093078 A1 WO 2008093078A1
Authority
WO
WIPO (PCT)
Prior art keywords
preform
carbon
infiltration
densified
carbon fibre
Prior art date
Application number
PCT/GB2008/000308
Other languages
English (en)
Inventor
Julio Joseph Faria
Original Assignee
Surface Transforms Plc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Surface Transforms Plc filed Critical Surface Transforms Plc
Priority to EP08701978A priority Critical patent/EP2109636A1/fr
Priority to CN200880010466A priority patent/CN101688007A/zh
Priority to JP2009547753A priority patent/JP2010516617A/ja
Publication of WO2008093078A1 publication Critical patent/WO2008093078A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
    • C04B35/573—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide obtained by reaction sintering or recrystallisation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02—Compositions of linings; Methods of manufacturing
    • F16D69/023—Composite materials containing carbon and carbon fibres or fibres made of carbonizable material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/526—Fibers characterised by the length of the fibers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/608—Green bodies or pre-forms with well-defined density
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0034—Materials; Production methods therefor non-metallic
    • F16D2200/0039—Ceramics
    • F16D2200/0047—Ceramic composite, e.g. C/C composite infiltrated with Si or B, or ceramic matrix infiltrated with metal

Definitions

  • This invention relates to a method for manufacturing brake and clutch discs, e.g. for motorised land vehicles or for aircraft, and to novel brake and clutch discs which are obtainable thereby. More particularly it concerns brake and clutch discs comprising carbon fibre-reinforced ceramic material such as may be obtained by using a liquid infiltration technique to generate a carbon matrix around the reinforcing carbon fibres, and thereafter impregnating the carbon matrix with molten silicon.
  • the resulting green bodies may then be shaped and/or joined together as appropriate, and are siliconised, for example by at least partial immersion in a bath of molten silicon or by a hot isostatic pressure treatment involving encapsulation with excess silicon in an evacuated container which is then subjected to high temperature and isostatic pressure.
  • Resin char procedures have the advantage of being relatively simple to operate, but do suffer a number of disadvantages.
  • the mould is normally filled with randomly oriented short carbon fibres, typically having an average length of less than 30 mm, more commonly less than 25 mm.
  • the fibres may, for example, be chopped from matchstick-like aggregates of carbon fibres which have been preimpregnated with resin; alternatively dry fibres chopped from a carbon fibre fabric such as a felt may be used, in which case resin is separately injected into the mould. It will be appreciated that the random orientation of the short carbon fibres necessarily limits the reproducibility of products obtained using resin char procedures.
  • Initial saturation typically occurs after 10-14 days; by this time the preform may have a density of the order of 1.4-1.5 g/cm 3 and will not yet have sufficient strength or integrity for use as a brake disc. It is therefore normal practice to remove the partially densified preform from the furnace and machine its surfaces in order to reopen the blocked pores, whereafter chemical vapour infiltration may be resumed. At least one further machining step and a third chemical vapour infiltration stage are normally required in order to obtain a disc with an acceptable density of around 1.8- 1.9 g/cfn 3 ; the total processing time is typically of the order of 150 days.
  • U.S. Patent No. 6,878,331 confirms that chemical vapour infiltration generally has to be repeated three to five times before the desired density is achieved. Discs obtaining in this way are not siliconised, and function well as aircraft brakes. They are, however, inappropriate for use in land vehicles, since they exhibit poor frictional properties at ambient temperatures and so cannot be used to provide occasional light braking.
  • 6,110,535 describes a technique for delivering a molten silicon composition into porous substrates of carbon composite material which may be obtained by densification using chemical vapour infiltration, this is normally the first step of a two stage densification process and is followed by a resin char densification so as to form grains of coke in the pores of the residual pore space remaining after the chemical vapour infiltration.
  • a further route to carbon-carbon fibre composite materials is the wetting monomer infiltration process described in, for example, WO-A-9964361 and U.S. Patent No. 6,756,112.
  • the carbon fibre preform is impregnated with one or more liquid monomers, for example polynuclear aromatic hydrocarbons such as naphthalene, preferably together with a polymerisation catalyst such as a Lewis acid.
  • the impregnated preform is then heated to promote polymerisation of the monomer(s), and the resulting polymer is then carbonised by further heating.
  • the products are said to compare favourably with composites prepared by multistage chemical vapour infiltration procedures carried out over a total period of 6-8 months.
  • the present invention is based on our finding that advantageous products may be obtained in particularly economical manner by siliconisation of incompletely densified preforms which have undergone initial densification by carbonisation involving only a single liquid infiltration step.
  • a method for the manufacture of a carbon fibre-reinforced ceramic brake or clutch disc which comprises preparing a carbon fibre preform having dimensions which substantially correspond to those of the desired disc, densifying said preform with carbon using only a single liquid infiltration step, and siliconising said densified preform by reaction with molten silicon.
  • a major advantage of the process of the invention is that, by avoiding the use of moulds, minimal constraints are placed on the shape of the carbon fibre preform, which may be varied as required without the need for major retooling, thereby rendering the manufacturing process highly versatile.
  • the preforms may therefore advantageously consist essentially of long fibres, for example having an average length of at least 50 mm, preferably at least 75, 100, 125 or 150 mm, since long fibres enhance the strength and integrity of the product.
  • long fibres enhance the strength and integrity of the product.
  • the reinforcing carbon fibres are essentially continuous, i.e. that the average fibre length is equal to or exceeds the radial distance between the inner and outer peripheries of the disc.
  • a particularly simple method of preparing such a continuous fibre preform is to cut it from a continuous sheet or cylinder of carbon fibre fabric, for example a woven fabric or a non- woven felt comprising alternating layers of carbon fibres laid at different angles, e.g. 0° and 90°.
  • the liquid infiltration step may be effected using wetting monomer infiltration as described in the aforementioned WO-A-9964361 and U.S. Patent No. 6,756,112, the contents of which are incorporated herein by reference.
  • Wetting monomers which may be used include furfural and polynuclear aromatic hydrocarbons, for example containing a total of 2-4 fused benzene rings, a portion of which may be hydrogenated, and optionally carrying one or more ring substituents such as C 1-4 alkyl (e.g. methyl or ethyl) groups.
  • Representative examples of such hydrocarbons include naphthalene, methylnaphthalene, tetrahydronaphthalene, phenanthrene, anthracene and pyrene; the use of naphthalene may be advantageous for reasons of its ease of handling and relatively low cost.
  • monomers having a relatively low melting point for example not exceeding 225°C, preferably not exceeding 175°C, may facilitate processing in order to impregnate the preform.
  • partially hydrogenated hydrocarbons such as 1,2,3,4-tetrahydronaphthalene which are liquid at ambient temperature may likewise be advantageous. Impregnation may be effected by dipping or immersing the preform in liquid
  • Polymerisation of the impregnated monomer may be effected by heating, for example to a temperature in the range 3OO-5OO°C; reaction times of about 2-6 hours, for example ca. 4 hours, may be appropriate.
  • the resulting polymer matrix may then be carbonised by further heating, for example to a temperature in the range 700-1400°C, e.g. over a period of 6-24 hours, such as 10-18 hours.
  • the total processing time for the wetting monomer infiltration process, i.e. comprising the impregnation, polymerisation and carbonisation steps, is advantageously about 12- 36 hours, preferably 20-30 hours, more preferably about 24 hours.
  • the preform may be directly impregnated with a liquid (including molten) polymer or resin, preferably having a low molecular weight (for example less than 5,000, preferably less than 3,000 or 2,500 and correspondingly low viscosity, which is then carbonised by heating as described above.
  • a liquid (including molten) polymer or resin preferably having a low molecular weight (for example less than 5,000, preferably less than 3,000 or 2,500 and correspondingly low viscosity, which is then carbonised by heating as described above.
  • the density of the preforms following liquid infiltration and carbonisation may conveniently be in the range 0.9-1.4 g/cm 3 .
  • the partially densified preforms may be graphitised prior to siliconisation, for example by heat treatment at ca. 2000°C or above, e.g. up to 2400°C, under non-oxidising conditions, e.g. under an inert gas such as argon or in vacuo, for example for a period of about 96 hours at peak temperature.
  • heat treatment at ca. 2000°C or above, e.g. up to 2400°C
  • non-oxidising conditions e.g. under an inert gas such as argon or in vacuo, for example for a period of about 96 hours at peak temperature.
  • Siliconisation may be effected in any appropriate manner such as is known in the art.
  • a dip process in which the optionally graphitised partially densified preform is at least partially immersed in a bath of molten silicon or a hot isostatic pressing procedure may be preferred.
  • the density of the siliconised product may, for example, be 1.9-2.4 g/cm 3 , e.g. about 2.0 g/cm 3 .
  • the product may be machined to its desired final dimensions either before or after siliconisation.
  • the former option may be preferred since the presiliconisation intermediate product is less hard and therefore more readily machinable than the siliconised end product.
  • the siliconised product may be subjected to a further carbon impregnation step.
  • Such treatment may be particularly advantageous in enhancing the lifetime and performance of aircraft brake discs, for example their wear resistance and frictional performance.
  • Such brake discs may reach extremely high operating temperatures during landing, on occasions exceeding the melting point of silicon (1410°C). Under such conditions free silicon within a siliconised carbon- carbon fibre composite disc may melt in the region of the disc surface, where it may either react to form silicon carbide or solidify as a thin film.
  • the former possibility may lead to increased wear of cooperating brake components by virtue of the highly abrasive nature of silicon carbide, whilst the latter may compromise the frictional properties of the disc.
  • Carbon impregnation of the siliconised partially densified preform may obviate this problem by reacting with and/or coating residual free silicon or otherwise providing a reserve of carbon within the disc structure to react with such free silicon should the disc temperature exceed the melting point of silicon during use. It may also be used to control the carbon/silicon and carbon/silicon carbide ratios, so as to provide an optimal balance between hardness, wear resistance and abrasive properties.
  • Such carbon impregnation is preferably effected in a single step, either by chemical vapour or liquid infiltration as hereinbefore described.
  • Carbon fibre-reinforced ceramic brake and clutch discs obtainable in accordance with the method of the invention are new and useful products and constitute a feature of the invention in their own right. Unlike products obtained using conventional resin char processing, the carbon matrix of the present products exhibits particularly high levels of adherence to the reinforcing fibres. The fibres are therefore well protected against unwanted interaction with silicon during siliconisation, and the products exhibit substantially enhanced strength and integrity compared to those of the prior art.
  • any free silicon content is effectively locked into the discs as a result of this impregnation treatment and may thus limit migration of silicon to the disc surface at operating temperatures which exceed the melting point of silicon.
  • a siliconsised carbon-carbon fibre composite brake or clutch disc characterised in that it contains impregnated carbon which overlies the silicon content.
  • the carbon matrix in resin char products of the prior art predominantly comprises amorphous glassy carbon
  • the matrix carbon content of the present products is comparatively more ordered, generally being in an isotropic, rough laminar or smooth laminar form. This is advantageous in that it permits more even and controlled interactions with silicon during siliconisation, permitting the manufacture of more uniform and reproducible products.

Abstract

Pour fabriquer des disques de frein et d'embrayage en céramique renforcée par des fibres de carbone, on enduit de silicone des préformes en fibres de carbone -carbone incomplètement densifiées produites au moyen d'une seule et unique étape d'infiltration de liquide. L'utilisation d'une seule et unique étape pour densifier la préforme réduit sensiblement les temps et les coûts de traitement tout en permettant de produire des produits finaux siliconés hautement efficaces qui peuvent ensuite être facultativement soumis à une autre étape d'imprégnation de carbone, par exemple, une seule et unique étape d'infiltration de vapeur chimique ou de liquide, afin d'optimiser leurs propriétés structurelles et de frottement, notamment en termes de stabilité à haute température..
PCT/GB2008/000308 2007-01-31 2008-01-31 Améliorations concernant les disques de frein et d'embrayage WO2008093078A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP08701978A EP2109636A1 (fr) 2007-01-31 2008-01-31 Améliorations concernant les disques de frein et d'embrayage
CN200880010466A CN101688007A (zh) 2007-01-31 2008-01-31 刹车和离合器片的改进
JP2009547753A JP2010516617A (ja) 2007-01-31 2008-01-31 ブレーキディスクおよびクラッチディスクの改良またはそれに関連する改良

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0701849.2 2007-01-31
GBGB0701849.2A GB0701849D0 (en) 2007-01-31 2007-01-31 Improvements in or relating to brake and clutch discs

Publications (1)

Publication Number Publication Date
WO2008093078A1 true WO2008093078A1 (fr) 2008-08-07

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PCT/GB2008/000308 WO2008093078A1 (fr) 2007-01-31 2008-01-31 Améliorations concernant les disques de frein et d'embrayage

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EP (1) EP2109636A1 (fr)
JP (1) JP2010516617A (fr)
CN (1) CN101688007A (fr)
GB (1) GB0701849D0 (fr)
WO (1) WO2008093078A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3000797A1 (fr) * 2014-09-24 2016-03-30 Rolls-Royce Corporation Procédé de fabrication d'articles composites à matrice céramique utilisant gelification
US10017426B2 (en) 2016-04-01 2018-07-10 Honeywell International Inc. High density carbon-carbon friction materials
US10710341B2 (en) 2012-05-16 2020-07-14 Petroceramics S.P.A. Shaped composite material

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19749462C1 (de) * 1997-11-10 1999-03-04 Deutsch Zentr Luft & Raumfahrt Verfahren zur Herstellung eines mit Kohlenstoff-Fasern verstärkten, keramisierten Formkörpers und Verwendung eines solchen Formkörpers
WO1999064361A1 (fr) * 1998-06-08 1999-12-16 United States Of America, As Represented By The Secretary Of The Air Force Materiaux composites a base de carbone et de ceramique obtenus par la polymerisation in situ de monomeres
US20060068150A1 (en) 2002-06-11 2006-03-30 Martin Henrich Tribological fiber composite component produced according to the tfp process
WO2007004482A1 (fr) * 2005-07-05 2007-01-11 Mitsubishi Chemical Functional Products, Inc. MATÉRIAU COMPOSITE EN SiC RENFORCÉ EN FIBRES DE CARBONE ET ÉLÉMENT DE GLISSIÈRE
WO2007012865A1 (fr) * 2005-07-29 2007-02-01 Surface Transforms Plc Améliorations concernant des disques de frein et d'embrayage

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19749462C1 (de) * 1997-11-10 1999-03-04 Deutsch Zentr Luft & Raumfahrt Verfahren zur Herstellung eines mit Kohlenstoff-Fasern verstärkten, keramisierten Formkörpers und Verwendung eines solchen Formkörpers
WO1999064361A1 (fr) * 1998-06-08 1999-12-16 United States Of America, As Represented By The Secretary Of The Air Force Materiaux composites a base de carbone et de ceramique obtenus par la polymerisation in situ de monomeres
US20060068150A1 (en) 2002-06-11 2006-03-30 Martin Henrich Tribological fiber composite component produced according to the tfp process
WO2007004482A1 (fr) * 2005-07-05 2007-01-11 Mitsubishi Chemical Functional Products, Inc. MATÉRIAU COMPOSITE EN SiC RENFORCÉ EN FIBRES DE CARBONE ET ÉLÉMENT DE GLISSIÈRE
EP1908740A1 (fr) * 2005-07-05 2008-04-09 Mitsubishi Chemical Functional Products, Inc. MATÉRIAU COMPOSITE EN SiC RENFORCÉ EN FIBRES DE CARBONE ET ÉLÉMENT DE GLISSIÈRE
WO2007012865A1 (fr) * 2005-07-29 2007-02-01 Surface Transforms Plc Améliorations concernant des disques de frein et d'embrayage

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10710341B2 (en) 2012-05-16 2020-07-14 Petroceramics S.P.A. Shaped composite material
EP3000797A1 (fr) * 2014-09-24 2016-03-30 Rolls-Royce Corporation Procédé de fabrication d'articles composites à matrice céramique utilisant gelification
US9630885B2 (en) 2014-09-24 2017-04-25 Rolls-Royce Corporation Method for making ceramic matrix composite articles
US10071936B2 (en) 2014-09-24 2018-09-11 Rolls-Royce Corporation Method for making ceramic matrix composite articles
US10689299B2 (en) 2014-09-24 2020-06-23 Rolls-Royce Corporation Method for making ceramic matrix composite articles
US10017426B2 (en) 2016-04-01 2018-07-10 Honeywell International Inc. High density carbon-carbon friction materials

Also Published As

Publication number Publication date
CN101688007A (zh) 2010-03-31
JP2010516617A (ja) 2010-05-20
EP2109636A1 (fr) 2009-10-21
GB0701849D0 (en) 2007-03-14

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