Abstract: A generally annular rotor insert is formed by casting a metal matrix composite. The rotor insert includes a pair of brake friction plates which are disposed in mutually spaced apart relationship. The brake friction plates include inner surfaces and generally parallel outer surfaces. At least one of the inner surfaces of the brake friction plates is provided with a plurality of spacing elements for engagement with the inner surface of the other one of the brake friction plates for maintaining the plates in predetermined spaced apart relationship. The rotor insert is placed in a rotor mold. A hat-shaped rotor body is cast in the rotor mold whereby the spacing elements are effective to maintain the plates in a predetermined spaced apart relationship.

Abstract: A composite disc brake rotor including a generally hat-shaped rotor body cast from an alloy, and a generally annular rotor insert cast from a metal matrix composite. The rotor body includes a generally centrally located mounting surface, and a radially outwardly extending annular portion. The rotor insert includes a pair of brake friction plates which are disposed in mutually spaced apart relationship. The brake friction plates include inner surfaces and generally parallel outer surfaces. The outer surfaces of the brake friction plates define a pair of brake friction surfaces adapted to be frictionally engaged by a pair of brake pads of a disc brake assembly. In accordance with the present invention, at least one of the inner surfaces of the brake friction plates is provided with spacing elements for engagement with the inner surface of the other one of the brake friction plates for maintaining the plates in a predetermined spaced apart relationship when the rotor body is cast in situ therewith.