Needled brake disks and methods

Abstract

The present disclosure provides a fibrous preform, comprising an annulus having at least one of an outer diameter portion or an inner diameter portion, the outer diameter portion extending radially inward from an outer diameter of the fibrous preform and the inner diameter portion extending radially outward from an inner diameter of the fibrous preform. In various embodiments, the fibrous preform further comprises a medial diameter portion disposed between the outer diameter and the inner diameter, wherein the medial diameter portion comprises a first needling profile, and the at least one of the outer diameter portion or the inner diameter portion comprises a second needling profile. In various embodiments, the first needling profile is less than the second needling profile.

What is claimed is: 
     
         1 . A method comprising:
 determining a first needling profile to optimize a first performance characteristic;   determining a second needling profile to optimize a second performance characteristic; and   needling a preform to achieve a non-uniform needling profile in a radial direction.   
     
     
         2 . The method of  claim 1 , wherein the needling comprises:
 needling a medial portion of the preform to achieve the first needling profile;   needling at least one of an inner diameter portion or an outer diameter portion of the preform to achieve the second needling profile.   
     
     
         3 . The method of  claim 2 , further comprising:
 determining a third needling profile configured to optimize a third performance characteristic, wherein the needling further comprises:   needling a heat affected zone disposed in the medial portion to achieve the third needling profile.   
     
     
         4 . The method of  claim 1 , further comprising:
 determining a fourth needling profile configured to optimize a fourth performance characteristic; and   needling the preform to achieve a non-uniform needling profile in an axial direction.   
     
     
         5 . The method of  claim 4 , wherein the needling comprises:
 needling an inner portion of the preform to achieve the fourth needling profile.   
     
     
         6 . The method of  claim 4 , wherein the needling is performed on individual layers of the preform. 
     
     
         7 . The method of  claim 4 , wherein the needling is performed on each fiber tow length of a plurality of fiber tow lengths of the preform. 
     
     
         8 . The method of  claim 7 , wherein each fiber tow length of the plurality of fiber tow lengths comprises:
 a first angle of orientation measured at an inner diameter of the preform, the first angle of orientation being repeated in a circular progression around the inner diameter; and   a second angle of orientation measured at an outer diameter of the preform, the second angle of orientation being repeated in a circular progression around the outer diameter of the preform;   wherein adjacent fiber tow lengths of the plurality of fiber tow lengths are each spaced apart at a substantially uniform distance.