When clutch boards are fabricated as friction sheets in automatic transmission of motorcars, their useless fragments are disposed of. In this study, an effective reuse of their waste clutch boards will be proposed. Clutch boards are composed of diatomaceous earth, carbon powder/fiber and phenol resin. Excess carbon in carbonized clutch boards was reacted with SiO formed from Si and SiO2 at 1500 °C in Ar to produce porous SiC sheets (79% porosity). High temperature treatment at 1700-1900 °C in vacuum made it possible to control the pore size of SiC sheets, having a main pore diameter range of 10 to 20 μm.
SiC sheets with porosity (79% to <60%) were also fabricated by heating carbonized/impregnated sheets with phenol resin in SiO gas at 1500 °C. SiC sheets obtained by the repeated cycle of impregnation/decomposition of resin heating at 1700 °C gave a tensile strength of 19 MPa.
When Aluminum-tri-sec-butoxide (ASB) solution was impregnated into SiC sheets oxidized at 1000-1200 °C in air and heated at 1400-1500 °C in Ar, SiC-mullite composite sheets with porosity (77%) were produced.