Manufacturing of Aircraft Brake System Components
The brake systemis one of the most critical safety systems in an aircraft,responsible for reducing speed and stopping the airplane after landing
or in emergency situations. The reliable performance of the brake system is directly related to the safety of passengers, crew, and the aircraft
structure . Manufacturing aircraft brake components requires precise design , advanced materials , and rigorous quality control due to their
demanding operational conditions—such as high temperatures, extreme pressure, and the need for rapid response.
Importance of the Brake System in Aircraft
Upon landing, an aircraft makes contact with the runway at speeds between 200 and 300 km/h . The force required for stopping is provided by
several systems:
Thrust reversers
Spoilers
Wheel brake system
Among these,the wheel brake system plays the final and most critical role in stopping the aircraft and must withstand extreme forces and heat.
Main Components of the Aircraft Brake System
The construction of the brake system involves the production and assembly of several sensitive and precise components. The main parts include:
Brake discs
Friction pads (carbon or composite materials)
Plates and torque tube assemblies
Hydraulic brake actuators
Valves and pressure control units
Sensors and electronic brake control units
All these parts must be made from specialized materials and machined with very tight tolerances.
Materials Used in Brake Component Manufacturing
Since brake components are exposed to high heat and pressure, the selected materials must exhibit specific thermal, mechanical, and friction
properties:
Brake Discs: Typically made from carbon-carbon composites for their high heat resistance , low weight , and stable friction performance.
Torque Tubes: Made from alloy steel or titanium to endure high torque and provide high hardness.
Hydraulic Cylinders: Constructed from aluminum or stainless steel for corrosion resistance and proper weight.
Friction Pads: Made from specialized composite alloys for consistent friction and wear resistance.
In modern aircraft—especially commercial jets—brake discs are predominantly made from carbon-carbon composites, which offer superior
performance and lighter weight compared to traditional steel discs.
Manufacturing Process of Brake System Components
The production of these components involves several specialized and precise stages:
Detailed Design Using CAD/CAM Software
Using tools like CATIA, NX, or SolidWorks, highly accurate 3D models are developed, allowing for stress, heat, and friction analysis.
Material Selection and Preparation
Materials are sourced with aerospace certifications (e.g., AMS, ASTM) and undergo mechanical and chemical property testing.
Precision Machining
Five-axis CNC machining is used to produce parts like torque tubes and hydraulic cylinder housings . Diamond or carbide tools are employed for
carbon-based components.
Carbon Composite Manufacturing
Carbon discs are typically manufactured using methods such as Chemical Vapor Infiltration (CVI) or controlled heat treatments, which can
take several weeks.
Heat Treatment and Coating
To enhance durability and heat resistance, processes like nitriding, surface hardening, and chrome or ceramic coating are applied.
Assembly and Functional Testing
All components are assembled with precision and tested under simulated conditions such as high pressure , elevated temperatures , and brake
application scenarios.
Quality Control for Aircraft Brake Components
Each brake system component must undergo stringent testing procedures:
Non-Destructive Testing (NDT): Radiographic, ultrasonic, and surface crack testing
Dimensional Inspection using CMM and lasers
Thermal resistance and fatigue testing
Friction testing (Dynamometer Tests)
Full system performance testing under simulated landing conditions
All manufacturing records, test data, and quality certifications must comply with international standards such as FAA, EASA, and AS9100.
Challenges in Brake Component Manufacturing
Enduring extremely high temperatures (over 1000°C)
Achieving high precision in machining and assembly
Ensuring consistent friction to avoid brake fluctuations
Requiring long component lifespan across many flight cycles
High cost of raw materials, especially carbon-carbon and titanium
Innovations in Aircraft Brake Systems
Recent years have seen the adoption of advanced technologies in aircraft braking systems, including:
Brake-by-Wire systems: Digital replacement for hydraulic systems
Carbon-Silicon Carbide (C/SiC) Discs: Offering even better performance than pure carbon
Smart sensors for temperature and wear: Enhancing safety and reducing maintenance time
Digital modeling and FEM analysis to extend component lifespan
Conclusion
Manufacturing aircraft brake system components is one of the most complex engineering processes in the aviation industry,requiring a combination
of precision design, specialized materials, advanced production technologies, and high-level quality control.Since flight safety depends on the prope
r functioning of the brakes, there is no room for error . With the advancement of technology and development of new materials , the future of this
field promises smarter, lighter, and more reliable brake systems for the next generation of aircraft.
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