LIGHTWEIGHT REINFORCED BRAKE DRUM AND METHOD FOR MAKING SAME

The invention provides a lightweight brake drum ( 10 ) comprising a lightweight, tubular inner member ( 14 ) having a reinforcement wrapping retention pattern (e.g., groove) cast in the exterior surface thereof, a length of reinforcement material (e.g., wrapped wire, cable, mesh, fibers, etc.) ( 16 ) in communication with a reinforcement retention pattern (e.g., a groove around the inner member) ( 14 ), the drum including an outer shell ( 18 ). The inner member ( 14 ) and the outer shell ( 18 ) are made of lightweight materials. Single, or multiple layers of reinforcement material (e.g. wrapping) are applied (e.g., wrapped) around the inner member ( 14 ) to support and inhibit expansion of the inner member ( 14 ). Because the reinforcement material ( 16 ) provides support against expansion, the inner member ( 14 ) and the outer shell ( 18 ) can be made of lightweight materials. In preferred embodiments, a bonding layer ( 66 ) is applied to the exterior surface of the inner member prior to application of the reinforcement material thereon. In preferred embodiments the reinforcement material comprises a low-impedance material such as copper along with another material that has good tensile strength characteristics (e.g., steel, composite fibers, Basalt-fibers, etc.). Preferably, the inner member comprises at least one material selected from the group consisting of a aluminum-based metal matrix composite (MMC) with a particulate reinforcement, ceramic matrix composite (CMC), and carbon graphite foam.