Technical info on CSiC rotors http://www.surfacetransforms.com/files/smmt_surface_transforms_article_march_2014.pdf
[quote]Manufacturer – Surface Transforms plc, UK
Surface Transforms plc (ST) is the UK’s leading manufacturer of ‘next-generation’ carbon fiber reinforced ceramic composite materials (CFRCs).
Carbon ceramics, or to give the full name, Carbon Fiber Reinforced Ceramics, are carbon composite materials which combine the stiffness and strength of carbon fiber in a carbon matrix, with the high temperature resistant properties of ceramics such as silicon carbide, which replace part of the carbon matrix material.
ST’s high-performance products are being commercialized with major industry partners for an expanding range of innovative global applications – using cutting-edge technology developed by the company.
Customer Applications
Surface Transforms’ SystemST carbon ceramic brakes are fitted to the Koenigsegg CCX, CCGT, Agera R, Ascari A10, and Callaway C16.
Features
Continuous fibers
3% elongation of fiber pre-cursors
High thermal conductivity/heat transfer
Homogeneous material structure
Solid ceramic component
High thermal and mechanical strength
Repairable
Improved cooling with greater surface-volume ratio
Lower operating temperature
Improved fade resistance
SystemST – Carbon Fiber Reinforced Ceramic Brakes
SystemST is the newest product in ceramic road car brakes, but ST is actually one of the oldest companies in ceramic brakes for other high-tech applications. During the last twenty years ST has been active in the aerospace, high speed rail, and motorsport markets. By combining cutting-edge aerospace technology with Formula 1 know-how tested to the highest specifications, this new product delivers the ultimate in high-performance brakes. ST’s ceramic brakes are designed to replace traditional carbon-carbon brake rotors used on aircraft and the cast iron brake rotors used on automotive applications.
Applications
Automotive brakes
Motorsport brakes
Aircraft brakes
Rail brakes
It is useful to understand the origins of the CFRC material to appreciate its capability. CFRC friction material for brake rotors was developed for (and paid for by) the European high speed rail industry, the heavy aircraft (airliner) industry, and the British Government through research grants. Bullet trains weigh hundreds of tons and have to stop from 300 km/hr. Airliners weigh up to 400,000 pounds and have to stop from 150 knots in 10,000 feet, on a limited number of tires/brakes. And every pound is precious on a commercial aircraft because the carrier has to pay for the fuel that carries that weight for millions of miles in an aircraft’s lifetime. Given those constraints, developing and producing this technology was cost-effective for those industries. The automotive market is a secondary beneficiary of all that R&D investment, without additional cost.
Manufacturing Technology – CFRCs & CSiC
ST has developed a proprietary process to convert carbon-carbon materials into Carbon Fiber Reinforced Ceramic (CFRC), also known as Carbon-Silicon Carbide (CSiC). The result is a material that can withstand temperatures of over 2,000°C, is 70% lighter than cast iron, and delivers outstanding quality and performance in a wide range of applications from friction applications within the automotive and aerospace industries to armored protection against high-velocity projectiles.
ST manufactures and supplies 3-D multi-directional carbon fiber and oxidized polyacrylonitrile (PAN) preforms to suit a variety of engineering applications. Carbon fiber preforms are mats of interwoven multi-directional carbon fibers (in the X-, Y-, and Z-axes), and are the basic materials that ST converts into ceramic brakes and discs using its patented technology. The carbon fibers in the mats are many times longer than the chopped fibers used in mold-cast carbon ceramic rotors, and are key to the strength and thermal advantages that CFRC rotors have over all other carbon ceramic rotors. These highly structured 3-D pre-forms are only possible in the precursor phase. Beyond the precursor stage, carbon fiber lacks the elongation properties needed to create the continuous woven and needled mats. This long fiber structure is kept for the entire production process until the rotor is finished.
PAN fiber sheets are needled together to create a PANOX preform. The future rotors are cut out of this preform. These “raw” discs are carbonized at more than 1500°C to convert the PAN fibers to carbon fibers. These carbonized rotors are then densified during a 14-day proprietary Chemical Vapor Infiltration (CVI) process. The rotors are then carbon-carbon. The rotors are then machined to the final geometry. Some faces are machined over thickness to allow for future machining.
Next, high rate silicon infiltration converts the carbon-carbon rotors to a carbon silicon carbide (CSiC) rotor within 16 hours. Melt infiltration with silicon is used for the formation of the ceramic phase. Molten silicon has a very low viscosity and will flow, water-like through the carbon composite, reacting with carbon to form silicon carbide. The design of equipment to facilitate this process and to deliver high quality composite materials is part of ST’s proprietary manufacturing process.
Finally, all faces are machined to the given tolerances and dimensions using polycrystalline diamond machine tooling which is required due to the hardness of the material. By manufacturing solid billets rather than molded castings, ST retains greater flexibility in the design and the dimensions of the brake discs. Finally, a strict x-ray scan and porosity check to ensure the same density throughout the entire rotor. By developing both discs and pads from its own CFRC materials, ST provides a balanced and high performance complete friction couple. ST recommends the Pagid STR-2 organic brake pad for use with CFRC brake discs.
Read More about CFRC Technology
Advantages of CFRC Rotors
Reduced Weight – The first improvement of a CFRC rotor over cast iron rotors is the reduced weight. The weight is reduced by approximately 50% over a same size cast iron rotor. So this means a savings of 9-18 pounds of rotating mass on each un-sprung corner of the car. As a result, the car feels as if it is “lighter”, responds better to the throttle, and handles significantly better. Handling is improved because the wheel is so much lighter, responds to the suspension springs faster, and follows the road much more closely. The next important advantage is the quicker steering response. Turning right and left is much “lighter” and the car turns in the desired direction much quicker and more accurately. Improved turn-in is a result of the reduced un-sprung weight and reduced gyroscopic effect of the high speed rotors. These are the advantages that you really feel; you don’t have to measure them. These advantages can be realized (and measured) in either improved performance or improved economy (fuel mileage). Economy improvements come from both overall vehicle weight reduction, as well as rotating mass reductions and their reduced acceleration loads on the engine.
Increased Life – A CFRC rotor is extremely strong and hard. Only polycrystalline diamond machine tooling is able to machine the surface of this rotor. The wear of this rotor is much less than the wear of a cast iron rotor. While replacing several cast iron rotors over the life of an automobile, the CFRC rotor can be left on the car and only the pads will ever need to be replaced. The fundamental difference between the CCB/CMC/CCM brake discs and the CFRC brake discs is that they are manufactured using discontinuous chopped carbon fibers where the ST discs are made of continuous carbon fiber woven into large mats. The mechanical integrity is superior because the strength of carbon lies in the direction and length of the fiber.
Since the structure of the CFRC rotor is the same friction material throughout the entire rotor, the lifetime is several times higher than the lifetime of the chopped fiber versions, which have friction surfaces laminated to their cores. The CFRC rotor can be re-surfaced several times, although this will take years of hard use and thousands of miles. In fact, CFRC rotors are durable enough to be transferred from car to car, as each car wears out, thus lasting the lifetime of multiple cars. All that is necessary is a change of hats and caliper supports.
Increased Thermal Capacity – As a result of the longer carbon fibers, the thermal conductivity and the thermal capacity of the CFRC rotors are much higher compared to ceramic rotors that are used on most production cars today. Those rotors are made out of a chopped fiber compound, so the fibers are much shorter, which results in poor thermal conductivity and low thermal capacity. The strength of those rotors is also reduced because of the lower material integrity. CFRC rotors can operate at much higher temperatures without damage to the brake, at 1200ºC disc surface temperatures. Ceramic brakes can store large quantities of heat so static and dynamic cooling is very important, as well as heat protection for other components near the brakes, such as wheel hubs and bearings.
The CFRC material is homogeneous, so it could theoretically wear down several mm with no change in performance. More importantly, the fibers are much longer, and transfer heat farther and faster than CCB and CCM, reducing heat buildup on the surface. CCB and CCM cannot reduce heat buildup as well, because of much shorter fibers in the composite, and the discontinuity between the friction surface laminate and the cast rotor core (in the case of the CCB). The specific heat of PANOX does not change, so that value is the same for CFRC, CCM, and CCB rotors.
Increased Thermal Conductivity – Another important advantage of the CFRC rotor is the much faster cooling compared to other ceramic rotors. The long fiber structure transfers the heat throughout the entire rotor quicker and thus dissipates the heat much quicker than a rotor with short chopped fibers that slowly transfers the heat. As a result of this intelligent design of the CFRC rotor, the performance and durability of the CFRC rotor is improved over normal cast iron rotors and other ceramic rotors, while brake fade and other heat-related issues are reduced or eliminated.
CFRC rotors do last longer on the track than other ceramic rotors, but not because they wear better. It’s because they transfer heat much better, and cannot de-laminate like some ceramic rotors (because they are not a laminate construction).
Resistance to Fading/Warping – CFRC rotors can operate with friction surface temperatures of 1200ºC without loss of friction performance, making them fade-resistant. The high thermal stability of CFRC also makes them resistant to warping, even at very high temperatures. However, brake pad material can accumulate in the minute pockets between the cross-weave on the surface of the CFRC rotor. The CFRC rotors can get thicker with use from the build-up of pad material. The rotors do not fade or warp, but the build-up can be un-even, which will feel like a warped rotor through the brake pedal. Also, excessive pad wear can be mistaken for brake fade and warped rotors. As the pads wear down, the pedal can get soft/spongy, and you can feel the normal vibration associated with thin pads. When using CFRC rotors, it is crucial that high performance brake fluid be used. The entire brake system is exposed to high heat and temperature under track conditions, so brake fluid can still boil for all the normal reasons (low grade Dot 3 fluid, old moisture-saturated fluid, contaminated fluid, etc.).
Reduced Cost – The Return On Investment (ROI) from CFRC rotors depends on how you use your brakes, which determines whether you will reach your break-even point. As an example, one driver went through 8 PCCB rotors ($32,000) in one year of track events. After switching to CFRC rotors ($24,000), the driver used the brakes for 17 months of track events, with no measurable wear. So, for that use case, the break-even point was reached very early. ROI can be improved in other ways: you only invest the time or money to install them once for the life of the car. That’s it. You never make that investment again (on that car). Also, you never risk losing time or money invested in a track weekend because your rotors wore out mid-weekend and you did not have spares.
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http://www.speed-werks.com/carbon-fiber-reinforced-ceramic