Brake rotor assembly

A brake rotor assembly comprising:

• (a) a first disc member having an inner disc surface and an outer disc surface and comprising:
• a first preform comprising ceramic particles and ceramic fibers with said first preform having an inner surface and an opposing outer surface and defining a plurality of voids;
• a first support element comprising a metal material, a first portion of said first support element disposed within said plurality of voids of said first preform between said inner surface and said opposing outer surface of said first preform for forming a metal matrix composite with said metal material of said first support element terminating at said outer surface of said first preform such that said opposing outer surface of said first preform remains exposed;
• said first support element further comprising a backing portion extending from said inner surface of said first preform such that said backing portion is outside of said first preform, said backing portion of said first support element formed of said metal material and defining at least a portion of said outer disc surface of said first disc member;
• said first support element of said first disc member further comprises a radially inward portion extending radially inwardly of said first preform such that said radially inward portion is outside of said first preform;
• and
• a first wear surface defined by said exposed outer surface of said first preform and by said first portion of said first support element, said first wear surface defining a portion of said outer disc surface of said first disc member;
• and
• (b) a second disc member coupled to said first disc member, said second disc member having an inner disc surface and an outer disc surface and comprising:
• a second preform comprising ceramic particles and ceramic fibers with said second preform having an inner surface and an opposing outer surface and defining a plurality of voids;
• a second support element comprising said metal material, a first portion of said second support element disposed within said plurality of voids of said second preform between said inner surface and said opposing outer surface of said second preform for forming a metal matrix composite with said metal material of said second support element terminating at said opposing outer surface of said second preform such that said opposing outer surface of said second preform remains exposed;
• said second support element further comprising a backing portion extending from said inner surface of said second preform such that said backing portion is outside of said second preform, said backing portion of said second support element formed of said metal material and defining at least a portion of said outer disc surface of said second disc member;
• said second support element of said second disc member further comprises a radially inward portion extending radially inwardly of said second preform such that said radially inward portion is outside of said first preform;
• and
• a second wear surface defined by said exposed outer surface of said second preform and by said first portion of said second support element, said second wear surface defining a portion of said outer disc surface of said second disc member;
• wherein said backing portion of each of said first support element and said second support element are located between said first wear surface and said second wear surface when said first disc member is coupled to said second disc member and
• wherein said inner disc surface of said first disc member is spaced apart from said second disc member when said first disc member is coupled to said second disc member.