Novel composite
disc brake rotor assemblies are provided, along with novel and efficient methods for manufacturing them. Preferably, the rotor assemblies comprise annular wear plates formed of particle reinforced aluminum-based
metal matrix composite (MMC),
ceramic matrix composite (CMC), or of ‘
carbon graphite foam.’ The wear plates, made of a first material, are attached to annular surfaces of a central rotor, made of a second material, by fusing bonding
layers between the wear plates and the rotor surfaces. The bonding
layers are comprised of at least one of a
metal alloy having a
melting temperature lower than that of either the first or second materials, and a high-temperature
adhesive. Preferably, the wear plates comprise projections that are positioned within adjacent receiving recesses in the center rotor. The bonding
layers and projections enhance thermal and acoustical transference between the wear plates and the center rotor section.
Carbon graphite foam provides for substantially enhanced heat transference. Use of the fusable binding layer, or
adhesive provides for an efficient, low cost method of manufacturing for composite
disc brake rotor assemblies.