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Carbon Fiber + Ceramic Car Brake Disc Manufacturing Process
- Jun 26, 2017 -

Ceramic review material can withstand more than 1000 degrees Celsius temperature, so the ceramic composite brake disc life is ordinary cast iron plate 6 times. The ceramic composite is made of carbon fiber reinforced silicon. In the production workshop, the carbon fiber is composed of two components: thermoplastic resin and carbon fiber raw material debris. The tiny carbon fiber yarns are intertwined to ensure the strength of the carbon fiber as a whole.

1. The carbon fiber mixture is fed into the aluminum mold with the shape of the brake disc by the brake device. When the first filling to half the mold volume, the workers will be in the mold around the hole marked with aluminum core and put on the fixed ring. These aluminum cores allow the brake discs to be ventilated so that the brakes can be ventilated and free from overheating when braking.

2. Next to the second filling , the entire mold space to be filled, and the drum with carbon fiber mixture flattened.

3. Then, the workers will cover the mold, and gently press the mold cover slightly pressed. After the entire mold was fed into a pressure cylinder with a capacity of 20 tons of pressure of 400 degrees Fahrenheit, the carbon fiber was pressed and the resin powder became plastic. When the mold is cooled enough to touch, the workers will dip it in cold water for 5 to 10 minutes. After full cooling, aluminum core can pull out.

4. Automatic laser system will scan the mold, to ensure that no all the aluminum core are pulled out. When everything is ready, open the front and back of the mold and remove the ring. The machine will grind the rough place and hit a small vents. Bake the ring into the oven for 2 days and continue to warm to 1800 ° F. During this period the material had a chemical reaction, and the plastic was carbonized.

5. The next step is to put five brackets in the crucible (high heat-resistant container), put the disk on the bracket, put a funnel in the center of the dish and inject the ceramic material (micro-silica fume). The crucible was then fired in the furnace for 24 hours, the plate temperature gradually rose to 3000 degrees Fahrenheit, silicon powder was melted. Liquid silicon began to penetrate the disk gap, and then generate a very powerful new material, called silicon carbide.

6. The brake disc will be baptized by the protective coating after the computer has automatically set the mounting hole on the edge of the disc. The coating can separate the brake disc from the oxygen because the oxygen will burn carbon at high temperatures. The antioxidant treatment greatly increases the life of the brake disc. The paint is cured in the furnace, leaving a layer of white residue. The robot removes it and then grinds the rest of the brake discs.

7. Each disc will be carefully tested, this high-precision instruments will take thousands of high-definition photos, the computer will be detailed in the nano-level analysis. To complete the brake disc, you have to install the head, head is linked to the carbon brakes and wheel hub of the central circular parts. Usually made of aluminum alloy or stainless steel, with screws mounted on the brake disc.