Patent ID: 7806243

Claim:
A process for making an improved titanium brake rotor, comprising: (a) providing titanium or a titanium alloy powder having an average particle size of about 1-20 microns, a mean aspect ratio of about 5 to 300, and specific surface area of at least about 25 m 2 /g; (b) mixing with said titanium or titanium alloy powder, nonmetallic material to provide a mixture; (c) providing a brake rotor mold: (i) pouring a first layer of said mixture into said mold; (ii) pouring a second layer of said titanium powder into said mold on top of said first layer; and (iii) pouring a third layer of said mixture on top of said nonmetallic powder layer; (d) compressing the powder in said mold to form a preformed brake rotor; and (e) sintering said preform to provide a brake rotor having first and second opposed sides having nonmetallic containing wear layers on each of said sides.