Petroceramics S.p.a.

Freni Brembo S.p.a.

C.i.r.a. (Centro Italiano Ricerche Aerospaziali)—s.c.p.a.

Massimiliano Valle

Paolo Vavassori

Marco Orlandi

Lorenzo Cavalli

Simone Turani

Andrea Gavazzi

Niccolo′ Ignazio Maria Pini

Roberto Vavassori

Konstantin Vikulov

Dino Norberto Boccaccini

Furio Rozza

Mirco Chiodi

Lucia Delledonne

Umberto Losa

Niccolò Ignazio Maria Pini

Giuseppe Carmine Rufolo

Mario De Stefano Fumo

Roberto Gardi

Stefania Cantoni

A chemical vapor infiltration (CVI) method for densifying at least one porous component includes placing the at least one porous component inside a crucible, bringing temperature inside the crucible to a value adapted to densify the porous component to transform it into a densified component, bringing pressure inside the crucible between 0.1 KPa and 25 KPa, once operational temperature and pressure are reached, flowing gas inside the crucible, gas being suitable for densifying the porous component to transform it into a densified component, and keeping an oxidizing environment outside the crucible, the external environment lapping against the crucible. The crucible is provided of at least one material having thermal conductivity greater than 30 W/mK from room temperature to at least 1000° C. selected from: sintered silicon carbide (SiC), silicon-infiltrated silicon carbide (Si—SiC), sintered boron carbide (B4C), silicon-infiltrated boron carbide (Si—B4C), sintered zirconium carbide (ZrC), silicon-infiltrated zirconium carbide (Si—ZrC), a combination of silicon carbide (SiC), boron carbide (B4C) and sintered and/or silicon-infiltrated zirconium carbide (ZrC).

Method and assembly for infiltration and rapid phase deposition of porous components

The invention relates to a pre-impregnated fibre-reinforced composite material in laminar form, obtained impregnating a fibrous mass with a polymeric binder composition and intended to be subjected to successive forming and pyrolysis operations to produce a fibre-reinforced composite ceramic material. The polymeric binder composition is based on one or more resins chosen from the group consisting of siloxane resins and silsesquioxane resins, and can optionally comprise one or more organic resins. The polymeric binder composition is a liquid with viscosity between 55000 and 10000 mPas at temperatures between 50&#xb0; C. and 70&#xb0; C. The polymeric binder composition forms a polymeric binding matrix, not cross-linked or only partially cross-linked that fills the interstices of the fibrous mass. The invention also relates to a method for making said pre-impregnated fibre-reinforced composite material in laminar form. The invention further relates to a fibre-reinforced composite ceramic material, obtained by forming and subsequent pyrolysis of a pre-impregnated fibre-reinforced composite material, as well as a method for making said material.

Pre-impregnated fibre-reinforced composite material and fibre-reinforced composite ceramic material, obtained by forming and subsequent pyrolysis of said pre-impregnated material

The present invention concerns a shaped composite material and a method for producing it. More specifically, the invention concerns a disc for a disc brake made from ceramic composite materials, usually known as 'CMC', i.e. 'Carbon Material Ceramic' or &#x201c;CCM&#x201d;, i.e. &#x201c;Carbon Ceramic Material&#x201d;. These materials consist of carbon matrices containing carbon fibres usually infiltrated with silicon and a product of reaction between C and Si, silicon carbide (SiC). More specifically, the invention concerns a shaped composite material comprising a inner layer () of CCM C/SiC/Si material comprising disorderly short filaments consisting mainly of carbon and respective outer layers (') of C/SiC/Si material and having an orderly fabric structure of mainly carbon fibres.

Shaped composite material

A brake disc made of fiber-reinforced material includes a braking band having a predetermined thickness. The method for making the brake discs includes setting up a winding mandrel and forming at least one layer of fibers having a predetermined width. The layer of fibers is impregnated with a binder resin. The impregnated layer is wound about the mandrel, forming a hollow cylindrical body having a predefined outer diameter and an inner diameter substantially equivalent to the mandrel diameter. The layer of fibers is wound about the mandrel in a winding direction substantially parallel to the lengthwise direction of the layer. The cylindrical body is heated to at least partly cross-link the binder resin and obtain a solid semi-finished cylindrical body. The cylindrical body is cut in slices transversely to the cylindrical body axis according to predetermined thicknesses. Each slice is a disc-shaped body defining the disc's braking band.

Method for making brake discs in fiber reinforced material and brake disc made with such method

The present invention relates to a method of printing a composite material (), for example polymeric, carbonaceous, siliconic or metallic comprising steps of:

Printing method and device, composite material

The invention illustrates a material for friction components of disc brakes comprising between 1% and 8% by weight of at least one preceramic resin and between 2% and 10% by weight of at least one organic resin. It also illustrates a friction component for a disc brake, a disc brake, and a process for producing such a material.

Material for friction components of disc brakes

Caliper bodies are provided for disc brakes suitable for being arranged astride of a disc for a disc brake, which include an attachment side portion, a non-attachment side portion and at least one bridge, said bridge being suitable for connecting such side portions and for being arranged astride of the disc, wherein the caliper body includes at least one portion made from thermoplastic material, reinforced with carbon fibres, with resistance to a temperature of at least 200&#xb0; C. Disc brakes which incorporate such caliper bodies are also provided.

Caliper bodies made from thermoplastic material

A method for treating a piece () made of a first porous material () with a second material () when this second material is in liquid state, said second material () being suitable for infiltration when a predetermined temperature range (DTi) and a predetermined field of infiltration pressure (Dpi), comprises the steps of: &#x2014;providing a crucible () suitable for containing the piece () and the second material () and capable of withstanding the temperatures and pressures for the infiltration of the second material () in the piece (); providing a cover () for the crucible () suitable for closing the crucible creating a chamber () inside the crucible; placing the piece () and the second material () in said crucible chamber (), when this second material is not yet in liquid state; &#x2014;subsequently closing the crucible () with the cover (); &#x2014;at a pressure (pa or pa1)&#x2014;unsuitable for the infiltrations of the second material in the first porous material, raising the temperature of the piece () and the second material () contained in the crucible up to a predetermined temperature (T) suitable for liquefying said second material () for making it suitable for infiltration in said piece () made of first porous material; &#x2014;subsequently, lowering the pressure to a predetermined pressure value (p) lower than the previous pressure (pa or pa1) and allow the infiltration of the second material () in said piece () made of first porous material ().

Method for infiltrating a porous material with a second material

Method for making a ceramic matrix material for brake friction components, in particular disc brakes, including the following operational phases: a) prepare a mixture of at least one siliconic type ceramic precursor, particles of hard materials suitable as abrasives, particles of substances suitable as lubricants and particles of metal materials; b) hot-press the mixture to obtain a green body; c) submit the green body to a process of pyrolysis in order to achieve ceramisation of the preceramic binder, thus obtaining a ceramic matrix material. The mixture includes a catalyst suitable for favoring reticulation of the ceramic precursor during the hot-pressing phase and the pyrolysis process is carried out at temperatures below 800&#xb0; C., more precisely between 400&#xb0; C. and 600&#xb0; C.

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Bergamo, Italy

Massimiliano Valle