Vehicular brake rotors

Abstract

Vehicular brake rotor formed by powder metallurgy including metals such as titanium powder.

1 . An improved titanium brake rotor comprised of a central layer of a metal or metal alloy sandwiched between two outside layers comprised of a mixture of metal or metal alloy and a nonmetallic material providing wear layers on said rotor. 
     
     
         2 . The brake rotor in accordance with  claim 1  wherein the metal or metal alloy is titanium or titanium alloy. 
     
     
         3 . The brake rotor in accordance with  claim 1  wherein the nonmetallic material is silicon carbide. 
     
     
         4 . The brake rotor in accordance with  claim 1  wherein the metal or metal alloy is titanium, steel or stainless steel or alloys thereof. 
     
     
         5 . The brake rotor in accordance with  claim 1  wherein the central layer contains nonmetallic material. 
     
     
         6 . The brake rotor in accordance with  claim 1  wherein the rotor is formed from powder material. 
     
     
         7 . The brake rotor in accordance with  claim 6  wherein said rotor is sintered at 1400° to 2200° F. 
     
     
         8 . The brake rotor in accordance with  claim 6  wherein said rotor is sintered at 1500° to 2100° F. 
     
     
         9 . The brake rotor in accordance with  claim 6  wherein said rotor was sintered using microwaves. 
     
     
         10 . The brake rotor in accordance with  claim 6  wherein said rotor has a density of at least 95%. 
     
     
         11 . The brake rotor in accordance with  claim 6  wherein said rotor has a density between 96 and 100%. 
     
     
         12 . An improved titanium brake rotor comprised of a central layer of a titanium or titanium alloy sandwiched between two outside layers comprised of a mixture of titanium or titanium alloy and silicon carbide to provide wear layers on said rotor. 
     
     
         13 . The titanium brake rotor in accordance with  claim 12  wherein said central layer is a double vane. 
     
     
         14 . The rotor of  claim 12  having a bond coat containing nickel, an intermediate coat comprising zirconium oxide, chromium carbide, and nickel, and a topcoat comprising zirconium oxide and chromium carbide applied to each side. 
     
     
         15 . The rotor of  claim 12  wherein said topcoat comprises about 65 to 75 parts by weight zirconia and about 25 to 35 parts by weight chromium carbide. 
     
     
         16 . The rotor of  claim 12 , the bond coat further containing aluminum. 
     
     
         17 . The rotor of  claim 12 , wherein the topcoat and the intermediate coat contain a lesser amount of nickel and aluminum than the bond coat. 
     
     
         18 . The rotor of  claim 12  including applying to first and second sides, coatings comprised of a bond coat of about 4.5 wt % aluminum and about 95.5 wt % nickel; an intermediate coat of about 70 parts by weight zirconia, 30 parts by weight of a composition as used for the bond coat, and 10 parts by weight chromium carbide; and a topcoat of about 70 parts by weight zirconium oxide and about 30 parts by weight chromium carbide. 
     
     
         19 . An improved titanium brake rotor comprised of a central layer of titanium or titanium alloy sandwiched between two outside layers comprised of a mixture of titanium and silicon carbide, thereby providing wear layers on said rotor. 
     
     
         20 . The titanium brake rotor in accordance with  claim 19  wherein said central layer is a double vane.