Abstract: An exemplary method for making a metal matrix composite vehicle component includes: using a mold including male and female die portions having mold surfaces and a plurality of spacers; heating the mold to a casting temperature; placing a ceramic preform on the plurality of spacers, the ceramic preform being spaced apart from at least one of the mold surfaces by the spacers; closing the mold to form a mold cavity between the mold surfaces of the male and female die portions, the ceramic preform being disposed within the mold cavity; providing molten metal into the mold cavity; and pressurizing the molten metal to a casting pressure for a casting duration to infiltrate the ceramic preform thereby forming the metal matrix composite vehicle component.

Abstract: The present application discloses a high-performance metal matrix composite (MMC) vehicle braking component, two methods of making a porous ceramic insert, a method of making an MMC comprising a porous ceramic insert, and a method of making an MMC not comprised of a porous ceramic insert. In one exemplary embodiment the porous ceramic insert is comprised of a ceramic compound and a sacrificial insert. In another exemplary embodiment the porous ceramic insert is comprised of one or more ceramic compounds and one or more ceramic preforms. The high performance MMC vehicle braking component has two distinct friction portions that extended from the outer surfaces to the thermal management portion of the high performance MMC vehicle braking component.

Abstract: The present application discloses a ceramic preform, a method of making a ceramic preform, a MMC comprising a ceramic preform, and a method of making a MMC. The method of making a ceramic preform generally comprises preparing reinforcing fibers, preparing a ceramic compound, and forming the compound into a desired shape to create the ceramic preform. In certain embodiments, the ceramic compound is formed as either a disc or a ring for use in a brake disc metal matrix composite. The metal matrix composite generally comprises the ceramic preform infiltrated with a molten metal to form the brake disc metal matrix composite. The method of making the metal matrix composite generally comprises heating the ceramic preform, placing the ceramic preform in a mold cavity of a die cast mold, and introducing molten metal into the mold cavity to infiltrate the ceramic preform to form the brake disc metal matrix composite.

Abstract: An exemplary method for making a metal matrix composite vented brake rotor includes: providing a first side plate; providing a second side plate; and welding the first and second side plates together. The first and second side plates have outer surfaces, inner surfaces, and metal matrix composite portions extending from the outer surfaces to a distance from the inner surface that is less than a thickness measured between the inner surface and outer surface. The inner surface of the first side plate includes a vent portion. The step of welding includes welding the first vent portion to the second inner surface to form the vented brake rotor, the vented brake rotor having a plurality of vents formed by the first and second inner surfaces and the first vent portion.

Abstract: An exemplary fuel tank includes a plastic container and an integral composite heat shield. The plastic container has an outer layer formed from high-density polyethylene. The heat shield has a heat reflective layer, an attachment layer, and a non-woven insulation layer having a bonding portion that includes bi-component fibers. The outer layer of the plastic container permeates and bonds to at least a portion of bonding portion of the non-woven insulation layer.

Abstract: An exemplary method for making a metal matrix composite vented brake rotor includes: providing a first side plate; providing a second side plate; and welding the first and second side plates together. The first and second side plates have outer surfaces, inner surfaces, and metal matrix composite portions extending from the outer surfaces to a distance from the inner surface that is less than a thickness measured between the inner surface and outer surface. The inner surface of the first side plate includes a vent portion. The step of welding includes welding the first vent portion to the second inner surface to form the vented brake rotor, the vented brake rotor having a plurality of vents formed by the first and second inner surfaces and the first vent portion.

Abstract: The present application discloses a ceramic preform, a method of making a ceramic preform, a MMC comprising a ceramic preform, and a method of making a MMC. The method of making a ceramic preform generally comprises preparing reinforcing fibers, preparing a ceramic compound, and forming the compound into a desired shape to create the ceramic preform. In certain embodiments, the ceramic compound is formed as either a disc or a ring for use in a brake disc metal matrix composite. The metal matrix composite generally comprises the ceramic preform infiltrated with a molten metal to form the brake disc metal matrix composite. The method of making the metal matrix composite generally comprises heating the ceramic preform, placing the ceramic preform in a mold cavity of a die cast mold, and introducing molten metal into the mold cavity to infiltrate the ceramic preform to form the brake disc metal matrix composite.

Abstract: An exemplary method for making a metal matrix composite vehicle component includes: using a mold including male and female die portions having mold surfaces and a plurality of spacers; heating the mold to a casting temperature; placing a ceramic preform on the plurality of spacers, the ceramic preform being spaced apart from at least one of the mold surfaces by the spacers; closing the mold to form a mold cavity between the mold surfaces of the male and female die portions, the ceramic preform being disposed within the mold cavity; providing molten metal into the mold cavity; and pressurizing the molten metal to a casting pressure for a casting duration to infiltrate the ceramic preform thereby forming the metal matrix composite vehicle component.

Abstract: An exemplary method for making a metal matrix composite vented brake rotor includes: providing a first side plate; providing a second side plate; and welding the first and second side plates together. The first and second side plates have outer surfaces, inner surfaces, and metal matrix composite portions extending from the outer surfaces to a distance from the inner surface that is less than a thickness measured between the inner surface and outer surface. The inner surface of the first side plate includes a vent portion. The step of welding includes welding the first vent portion to the second inner surface to form the vented brake rotor, the vented brake rotor having a plurality of vents formed by the first and second inner surfaces and the first vent portion.