Abstract
This work addresses the integration of ceramic matrix composites (CMCs) and an Al alloy to obtain mechanically reliable and in-service durable CMC-Al alloy joints for high-performance road brake discs. Such a braking system is based on the use of CMC discs mounted onto a hub or stub axle by means of a mounting bell, manufactured in aluminium alloy. The CMCs, developed by Brembo SGL Carbon Ceramic Brakes (BSCCB), consist of an Si–SiC matrix reinforced with short carbon fibre bundles.An epoxy adhesive, Supreme 42HT-2, whose curing parameters had been characterised to establish the best joining process, was chosen as a potential joining material as it showed the most promising results. CMC/Supreme 42HT-2/Al alloy joined samples, obtained following the supplier's recommended curing process, exhibited a shear strength of 31.6 ± 7.2 MPa, while samples processed with a post thermal treatment at 200 °C for 10 min showed a value of 38.2 ± 6.4 MPa. The influence of corrosion, in a high-salinity environment, on the mechanical strength of the joined samples is also reviewed and discussed. Thermal cycles (from room temperature to 200 °C) and the corrosive environment did not affect the mechanical properties of the joints or the failure propagation mode to any great extent.
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