A High-Efficiency Technology for Manufacturing Aircraft Carbon Brake Discs with Stable Friction Performance

A binary C/C brake disc (i.e., the test brake disc) was prepared with a C/C (pyrolytic carbon/resin carbon) matrix using modified natural gas as the carbon source through the isothermal chemical vapor infiltration (ICVI) process with a directed flow and the pressure impregnation carbonization (PIC) process with liquid-phase furfural acetone resin. The microstructural, mechanical, thermal, friction and wear properties of the test brake disc were comprehensively analyzed and compared with commercial ones. The results showed that the production efficiency of the test brake disc was 36% higher than that of the commercial ones, which were manufactured through a thermal-gradient chemical vapor infiltration (TCVI) process. The favorable mechanical and thermal properties of the test brake disc were comparable to the commercial ones. While the test brake disc had a more consistently rough laminar microstructure on the worn surface of the brake disc than the commercial ones, this avoided the annular grinding grooves on the worn surface after the braking tests. In addition, the test brake disc had a stable friction coefficient with a low dispersion coefficient of 3.90%, which would improve the friction stability of C/C brake discs used in aircrafts.