Abstract: Method of joining carbon-carbon composite pieces together, e.g. in the refurbishment of aircraft brake discs.

Abstract: A method of increasing carbon disc utilization in aircraft carbon brakes. A brake (10) is initially assembled with a heat stack (16) of alternating thick rotors (R1–R4) and thin stators (S1–S3). When the piston (20) is fully extended, it is retracted and a spacer (30) is inserted between the piston (20) and the original heat stack (16). The brake (10) is then subjected to a another half tour. After this half tour, the brake (10) is overhauled, and the now-thin discs (S1–S3, PP and BP) are replaced with thick discs to form another heat stack (50). For the next half tour, no spacer is used between the piston (20) and the heat stack (50). At the end of this half tour and the piston (20) is fully extended, a spacer (70) is inserted between the piston (20) and the heat stack (50). The heat stack (50) remains unchanged. For the next half tour, it is accomplished with the spacer (70). When this half tour is completed, the worn out rotors are replaced with new thick rotors and the process can be repeated.

Abstract: A friction disc assembly having an annular structural core (40) and at least one friction lining disc (30). The annular structural core (40) is made from a strength-optimized carbon carbon composite and the friction lining discs (30) from a friction-optimized carbon carbon composite. Each friction lining disc (30) is provided with a mounting surface (31) and a wear surface (32). The structural core (40) includes at least one mounting surface (41). The mounting surfaces (31,41) may include corresponding sinusoidally-shaped wave patterns for increasing the surface area of a contact zone between the friction lining discs (30) and a reusable structural core (40).

Abstract: A method of increasing carbon disc utilization in aircraft carbon brakes. A brake (10) is initially assembled with a heat stack (16) of alternating thick rotors (R1-R4) and thin stators (S1-S3). When the piston (20) is fully extended, it is retracted and a spacer (30) is inserted between the piston (20) and the original heat stack (16). The brake (10) is then subjected to a another half tour. After this half tour, the brake (10) is overhauled, and the now-thin discs (S1-S3, PP and BP) are replaced with thick discs to form another heat stack (50). For the next half tour, no spacer is used between the piston (20) and the heat stack (50). At the end of this half tour and the piston (20) is fully extended, a spacer (70) is inserted between the piston (20) and the heat stack (50). The heat stack (50) remains unchanged. For the next half tour, it is accomplished with the spacer (70). When this half tour is completed, the worn out rotors are replaced with new thick rotors and the process can be repeated.

Abstract: A friction disc assembly having an annular structural core (40) and at least one friction lining disc (30). The annular structural core (40) is made from a strength-optimized carbon—carbon composite and the friction lining discs (30) from a friction-optimized carbon—carbon composite. Each friction lining disc (30) is provided with a mounting surface (31) and a wear surface (32). The structural core (40) includes at least one mounting surface (41). The mounting surfaces (31,41) may include corresponding sinusoidally-shaped wave patterns for increasing the surface area of a contact zone between the friction lining discs (30) and a reusable structural core (40).