Abstract: A method for manufacturing a ferrous rotational member including the steps of turning a first portion of the friction surface at a sufficient feed rate to provide a first deformed layer on the first portion of the friction surface; fine turning a second portion of the friction surface at a sufficient feed rate to provide a second deformed layer on the second portion of the friction surface; burnishing the first and second portions of the friction surface to achieve a predetermined roughness; and nitrocarburizing the rotational member at a time and temperature sufficient for the diffusion of nitrogen atoms and carbon atoms through the deformed layer to form hardened casings having variable thickness. The ferrous rotational member may be that of a brake rotor having a hub surface and a friction surface, where the hub surface and friction surface have a variable thickness hardened casing.

Abstract: A number of variations may include a ferritic nitrocarburized part comprising steel, wherein the ferritic nitrocarburized steel has a tensile strength exceeding the parent steel material and sufficient ductility, bendability, and flangeability to support subsequent flanging and press-fitting of bushings. Exact strength increases and bendability will be dependent on exact process and alloy combinations.

Abstract: A method for manufacturing a ferrous rotational member including the steps of turning a first portion of the friction surface at a sufficient feed rate to provide a first deformed layer on the first portion of the friction surface; fine turning a second portion of the friction surface at a sufficient feed rate to provide a second deformed layer on the second portion of the friction surface; burnishing the first and second portions of the friction surface to achieve a predetermined roughness; and nitrocarburizing the rotational member at a time and temperature sufficient for the diffusion of nitrogen atoms and carbon atoms through the deformed layer to form hardened casings having variable thickness. The ferrous rotational member may be that of a brake rotor having a hub surface and a friction surface, where the hub surface and friction surface have a variable thickness hardened casing.

Abstract: A brake rotor comprising a brake pad wear surface; a hat surface; and a decorative insert comprising an insert material, the decorative insert disposed on the brake pad wear surface, the hat surface, or both; wherein at least one of a friction coefficient between the decorative insert and a brake pad is substantially the same as a friction coefficient between the brake pad wear surface and the brake pad, a wear rate of the decorative insert is substantially the same as or greater than a wear rate of the brake pad wear surface, or a wear rate of the decorative insert is substantially the same as or greater than a wear rate of the hat surface; and at least a portion of the decorative insert is visible on the brake pad wear surface, the hat surface, or both.

Abstract: A number of variations may include a ferritic nitrocarburized part comprising steel, wherein the ferritic nitrocarburized steel has a tensile strength exceeding the parent steel material and sufficient ductility, bendability, and flangeability to support subsequent flanging and press-fitting of bushings. Exact strength increases and bendability will be dependent on exact process and alloy combinations.

Abstract: A number of variations may include a ferritically nitrocarburized vehicle component comprising a compound zone and a friction surface at an outer edge of the compound zone wherein the friction surface is configured for engagement with a corresponding friction material, and wherein the compound zone comprises a nitride layer comprising epsilion iron nitride, Fe3N and gamma prime iron nitride Fe4N.

Abstract: A brake rotor comprising a brake pad wear surface; a hat surface; and a decorative insert comprising an insert material, the decorative insert disposed on the brake pad wear surface, the hat surface, or both; wherein at least one of a friction coefficient between the decorative insert and a brake pad is substantially the same as a friction coefficient between the brake pad wear surface and the brake pad, a wear rate of the decorative insert is substantially the same as or greater than a wear rate of the brake pad wear surface, or a wear rate of the decorative insert is substantially the same as or greater than a wear rate of the hat surface; and at least a portion of the decorative insert is visible on the brake pad wear surface, the hat surface, or both.

Abstract: A ferritically nitrocarburized rotational member of a vehicle brake is disclosed, including a rotational member having a friction surface configured for braking engagement with a corresponding friction material. A compound zone is disposed at the friction surface. An exposed surface of the compound zone is exposed to an atmosphere. The area of the exposed surface includes from about 0 percent to about 14 percent graphite.

Abstract: A number of variations may include a brake rotor having a surface oxide layer and methods of making the same.

Abstract: A number of variations may include a product that may include at least one working friction surface that may include at least two layers that may include a compound layer and a nitrogen diffusion layer wherein the compound layer may have a porosity ranging from about 19% to about 50%.

Abstract: One variation includes a friction material and method of manufacture thereof wherein the friction material includes a transfer layer on a ferritically nitrocarburized component, wherein the transfer layer may be fabricated from glass, rubber, carbon, aramid fiber, filler material, abrasive, or a high-temperature resin.

Abstract: One variation includes a friction material and method of manufacture thereof wherein the friction material includes a transfer layer on a ferritically nitrocarburized component, wherein the transfer layer may be fabricated from glass, rubber, carbon, aramid fiber, filler material, abrasive, or a high-temperature resin.

Abstract: A method for improving corrosion resistance in FNC cast iron substrates without the need for additional coating or painting. The exemplary methods remove a portion of the FNC coating applied to a cast iron substrate, preferably through polishing, to expose the epsilon phase portion of the compound area. The epsilon phase portion is thought to provide improved corrosion protection as compared to non-polished FNC cast iron substrates. One exemplary product that may be provided with improved corrosion protection according to the above method is a brake rotor having a FNC treatment.

Abstract: A ferritically nitrocarburized rotational member of a vehicle brake is disclosed, including a rotational member having a friction surface configured for braking engagement with a corresponding friction material. A compound zone is disposed at the friction surface. An exposed surface of the compound zone is exposed to an atmosphere. The area of the exposed surface includes from about 0 percent to about 14 percent graphite.

Abstract: A wheel assembly for a non-driven wheel includes a rotating wheel hub with a shaft portion supporting a bearing inner race. A magnetic encoder is mounted for rotation with the shaft portion. A non-rotating component radially surrounds the shaft portion and has a bearing outer race. A cap is secured to the non-rotating component and covers the outer and inner races, the shaft portion and the magnetic encoder inboard of the races to seal an inboard side of the outer and inner races. A sensor is mounted to a non-rotating vehicle steering member externally to, not covered by, and not extending through the cap. The sensor is configured to deflect to be biased into continuous contact with an outer surface of the cap to read the magnetic encoder through the cap without extending through the cap.

Abstract: A number of variations may include a brake rotor having a surface oxide layer and methods of making the same.

Abstract: Ferritic nitrocarburized surface treatment of cast iron brake rotors providing oxidation resistance, good braking performance and absence of distortion. Machined brake rotors are pre-heated, then immersed into a high temperature molten nitrocarburizing salt bath for a first predetermined dwell time. After removing the brake rotors from the nitrocarburizing salt bath, the brake rotors are directly immersed into an oxidizing salt bath at a lower temperature than the nitrocarburizing salt bath so that the brake rotors are thermally quenched. After a predetermined second dwell time in the oxidizing salt bath, the brake rotors are removed therefrom and further cooled to room temperature, either by water application thermal quenching or slow cooling in air. A fixture provides stable holding the brake rotors with a minimum of contact during placement in the salt baths.

Abstract: Ferritic nitrocarburized surface treatment of cast iron brake rotors providing oxidation resistance, good braking performance and absence of distortion. Machined brake rotors are pre-heated, then immersed into a high temperature molten nitrocarburizing salt bath for a first predetermined dwell time. After removing the brake rotors from the nitrocarburizing salt bath, the brake rotors are directly immersed into an oxidizing salt bath at a lower temperature than the nitrocarburizing salt bath so that the brake rotors are thermally quenched. After a predetermined second dwell time in the oxidizing salt bath, the brake rotors are removed therefrom and further cooled to room temperature, either by water application thermal quenching or slow cooling in air. A fixture provides stable holding the brake rotors with a minimum of contact during placement in the salt baths.

Abstract: Ferritic nitrocarburized surface treatment of cast iron brake rotors providing oxidation resistance, good braking performance and absence of distortion. Machined brake rotors are pre-heated, then immersed into a high temperature molten nitrocarburizing salt bath for a first predetermined dwell time. After removing the brake rotors from the nitrocarburizing salt bath, the brake rotors are directly immersed into an oxidizing salt bath at a lower temperature than the nitrocarburizing salt bath so that the brake rotors are thermally quenched. After a predetermined second dwell time in the oxidizing salt bath, the brake rotors are removed therefrom and further cooled to room temperature, either by water application thermal quenching or slow cooling in air. A fixture provides stable holding the brake rotors with a minimum of contact during placement in the salt baths.

Abstract: A ferritically nitrocarburized rotational member of a vehicle brake is disclosed, including a rotational member having a friction surface configured for braking engagement with a corresponding friction material. A compound zone is disposed at the friction surface. An exposed surface of the compound zone is exposed to an atmosphere. The area of the exposed surface includes from about 0 percent to about 14 percent graphite.