Carbon-silicon carbide brake preforms are manufactured by carbonizing a
blend of carbon (e.g., polyacrylonitrile) fibers and thermosetting pitch
resin, optionally along with a lubricant such as graphite,.to provide an
intermediate product having open porosity and subsequently filling the
pores of the intermediate product with silicon by a melt infiltration
process. Molded articles that consist principally of carbon, that have
relatively high strength and resistance to decomposition by frictional
heat, and that are suitable for melt infiltration with silicon, are
produced by, e.g.: coating randomly oriented polyacrylonitrile-derived
carbon fibers, optionally mixed with finely divided carbon powder, with a
thermosetting blend of (a) pitch and (b) an organic medium, at an
elevated temperature to form a viscous molding compound; molding the
compound at a low pressure and elevated temperature so that a solid
compact is obtained; stripping a molded article made of said compound
from the mold; optionally heating the molded article at gradually
increasing temperatures to insure complete condensation within the
article; and carbonizing the condensed molded article in an inert
atmosphere at gradually increasing temperatures to produce a molded C/C
intermediate article suitable for melt-infiltration with silicon. The
preforms may be configured in the form of a disc brake rotor or a disc
brake pad.