Abstract: A brake disc arrangement has a mounting portion formed of a metal, with a plurality of radial protuberances extending radially outward therefrom. The radial protuberances each have a radially distal tip portion, and a ceramic coating is applied to the radially distal tip portion of the radial protuberances. The brake plate portion is cast so as to surround the radially distal tip portions. However, it is isolated therefrom by the ceramic coating. At least some of the radially distal tip portions are formed of metal having a microstructure created by electrical discharge machining to increase dampening. A sand core within a core box holds the mounting portion in a predetermined fixed orientation. The molten metal is poured into the core box mold, and the metal brake plate portion is prevented by the ceramic coating from welding to any of the plurality of radial protuberances.

Abstract: A brake disc arrangement has a mounting portion formed of a metal, with a plurality of radial protuberances extending radially outward therefrom. The radial protuberances each have a radially distal tip portion, and a ceramic coating is applied to the radially distal tip portion of the radial protuberances. The brake plate portion is cast so as to surround the radially distal tip portions. However, it is isolated therefrom by the ceramic coating. At least some of the radially distal tip portions are formed of metal having a microstructure created by electrical discharge machining to increase dampening. A sand core within a core box holds the mounting portion in a predetermined fixed orientation. The molten metal is poured into the core box mold, and the metal brake plate portion is prevented by the ceramic coating from welding to any of the plurality of radial protuberances.