Surface Transforms uses a unique, patented process to produce our next generation carbon-ceramic material. This process delivers the numerous advantages of the CCST material and our stringent quality standards ensure top-quality brake discs.
STAGE 1: CARBON FIBRE PREFORM
A unique 3D structure of carbon-fibre is weaved together from multiple layers of carbon-fibre cloth to form the base carbon material (pre-form).
STAGE 2: CARBONISATION
The carbon fibre pre-forms are heated to a temperature of (1,000-3,000° C) in a furnace filled with a gas mixture that does not contain oxygen. The lack of oxygen prevents the carbon from burning in the very high temperatures. As the pre-forms are heated, they begin to lose their non-carbon atoms, plus a few carbon atoms, in the form of various gases including water vapor, ammonia, carbon monoxide, carbon dioxide, hydrogen, nitrogen, and others. As the non-carbon atoms are expelled, the remaining carbon atoms form tightly bonded carbon crystals that are aligned more or less parallel to the long axis of the fibres.
STAGE 3: CHEMICAL VAPOUR INFILTRATION (CViST)
Surface Transforms have developed their own process CVIST based on the Chemical Vapor Infiltration method of Ceramic Matrix Composites fabrication. This is a process in which reactant gases diffuse into the porous preform and form a deposition. Deposited material is a result of chemical reaction occurring on the fibers surface. The deposition fills the space between the fibres, forming composite material in which matrix is the deposited material and dispersed phase is the fibres of the preform.
STAGE 4: HEAT TREATMENT
Following CViST, the parts are placed in a furnace and taken through a further cycle at very high temperature.
STAGE 5: GREEN-STATE MACHINING
At this stage, the parts are solid blanks of close to the finished dimensions but not yet as hard as the final part. Most of the machining of the component features is done at this stage, as machining after the next stages is expensive and time consuming due to the high hardness of the material.
STAGE 6: MELT INFILTRATION (MiST)
ST-developed process of melt infiltration deposits the Silicon Carbide into the Carbon pre-form to produce the final composite material – CSiC.
STAGE 7: FINAL MACHINING
A final machining process is required to achieve the specific tolerances required for brake components.
STAGE 8: ANTI-OXIDANT COATING
Before parts are completed, a self-healing, anti-oxidant coating is added to prevent oxidation and increase the life of the part.
STAGE 9: INSPECTION
A CMM (co-ordinate measuring machine) inspection of each part along with DTV (disc thickness variation) measurements is performed to ensure all parts meet the strict tolerances required by our customers.
STAGE 10: DESPATCH
The final parts are packaged in our Surface Transforms bespoke shipping boxes and despatched by courier to our customers around the world.