Systems and methods for forming a layer onto a surface of a solid substrate and products formed thereby
AssigneeAts Mer, LLC
InventorsLori Bracamonte, James Withers, Jowie Abcede
Life of this patent
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Abstract
A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.
Claims16
A method for forming a metal/ceramic composite friction surface layer bonded to a surface of a solid metal substrate in the form of a hub-disc assembly, said method comprising:
- loading the metal substrate into a friction stir processing apparatus having a rotating head;
- positioning the rotating head facing the substrate and applying heat and pressure onto the surface of the substrate while rotating the head;
- feeding a powder metal, and a ceramic particle feed mixture between the rotating head and the substrate under sufficient pressure such that friction between the rotating head, the mixture and the substrate raises the temperature of the surface of the substrate to cause the surface of the metal substrate to melt under the rotating head, whereupon a metal/ceramic composite friction surface layer consisting of particles of said ceramic particulate feed and said powder metal feed in the mixture is encapsulated in the melt and, upon cooling, bond to the surface of the substrate without any intervening layer, whereby to increase friction and enhance wear resistance of the surface of the metal substrate.
Dependencies are inferred from the claim text.