CN105439603A - 树脂分散碳化铌碳化硅-碳纤维摩擦材料的制备方法 - Google Patents

树脂分散碳化铌碳化硅-碳纤维摩擦材料的制备方法 Download PDF

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CN105439603A
CN105439603A CN201610014361.0A CN201610014361A CN105439603A CN 105439603 A CN105439603 A CN 105439603A CN 201610014361 A CN201610014361 A CN 201610014361A CN 105439603 A CN105439603 A CN 105439603A
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唐竹兴
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Abstract

树脂分散碳化铌碳化硅-碳纤维摩擦材料的制备方法，其特征在于，将密度为0.1~1.8g/cm3石墨化的碳纤维毯进行渗碳处理后进行树脂分散碳化铌填充处理，再进行沉积碳化硅处理，再进行埋入渗硅处理，然后在氮气气氛中氮化处理制得树脂分散碳化铌碳化硅-碳纤维摩擦材料。本发明是采用石墨化碳纤维毯通过渗碳、填充碳化铌、沉积碳化硅、埋入渗硅及氮化等步骤实现摩擦材料的制备，所制备的摩擦材料高强度、高韧性、高摩擦性能，能适应各种气候条件的摩擦材料。

Description

树脂分散碳化铌碳化硅-碳纤维摩擦材料的制备方法
技术领域
本发明涉及一种碳纤维和陶瓷材料复合的摩擦材料的制备方法，属于复合材料制备技术领域。
背景技术
摩擦材料目前主要采用的是碳纤维和碳（C/C）复合材料，由于C/C复合材料的耐磨性能相对较低，人们正在寻求耐磨性能更高的摩擦材料的制备方法。另外，C/C复合材料在潮湿的环境中，它的摩擦性能会降低，给使用带来严重的安全隐患。
发明内容
本发明的目的在于提供一种能克服上述缺陷、实现制备更高强度、更高摩擦性能及适应各种气候条件的摩擦材料的制备方法。其技术方案为：
树脂分散碳化铌碳化硅-碳纤维摩擦材料的制备方法是将密度为0.1~1.8g/cm3石墨化的碳纤维毯进行渗碳处理后进行树脂分散碳化铌填充处理，再进行沉积碳化硅处理，再进行埋入渗硅处理，然后在氮气气氛中氮化处理制得树脂分散碳化铌碳化硅-碳纤维摩擦材料，具体步骤如下：
（1）将密度为0.1~1.8g/cm3石墨化的碳纤维毯在900~1100℃温度下通入丙烷气和氮气的混合气体，丙烷气:氮气的摩尔比为1:4~6，流量控制在50~600ml/min，渗碳处理10~24小时获得渗碳碳纤维毯；
（2）将上述渗碳碳纤维毯浸入粒度小于0.3μm含量为5~20%碳化铌的树脂浆料里，置于超声波清洗器中填充碳化铌处理30~50分钟，取出干燥后制得填充碳化铌碳纤维毯，其中树脂浆料为含酚醛树脂5~20%的乙醇溶液；
（3）将上述填充碳化铌碳纤维毯在900~1100℃温度下通入三氯甲基硅烷气、氢气和氩气的混合气体，沉积碳化硅处理10~24小时获得沉积碳化硅碳纤维毯，其中，三氯甲基硅烷气:氢气:氩气的摩尔比为1:3~5:3~5，流量为50~600ml/min；
（4）将上述沉积碳化硅碳纤维毯埋入渗硅料里，在真空气氛下1500~1800℃的温度下渗硅处理3~5小时制得渗硅碳纤维毯，其中，渗硅料为硅粉30~50%和直径为0.5~3mm炭粒50~70%的混合物外加5~15%浓度为0.2~0.6%聚乙烯醇水溶液均匀混合干燥后制得；
（5）将上述渗硅碳纤维毯在1350~1700℃的温度下氮化处理10~24小时制得树脂分散碳化铌碳化硅-碳纤维摩擦材料。
本发明与现有技术相比，其优点为：
1、本发明使用的碳纤维毯是石墨化的碳纤维毯，或石墨化的针刺碳纤维毯，或石墨化的编织碳纤维布，或石墨化的三维编织碳纤维织块；
2、本发明制备的摩擦材料是由碳纤维和碳化硅、碳化铌、氮化硅复合的一种高强度、高摩擦性能、适应各种气候条件下的摩擦材料；
3、通过渗碳、填充碳化铌、沉积碳化硅、埋入渗硅及氮化等步骤实现摩擦材料的制备，渗碳和沉积碳化硅两个步骤是为了保护碳纤维表面不受破坏而在碳纤维表面赋予的炭涂层和碳化硅涂层，因为在渗硅的过程中碳化硅涂层会阻挡硅蒸汽的渗入，碳化硅涂层一旦渗漏，渗碳涂层与硅蒸汽反应生成碳化硅进一步阻挡硅蒸汽，从而保护碳纤维表面不受破坏；
4、碳纤维毯具有很高的气孔率，单靠渗碳和沉积碳化硅会需要很长时间才能达到致密化，制造成本很高，采用填充碳化铌和埋入渗硅的方法填充碳纤维毯的空隙就会非常方便，省时省力，同时填充碳化铌能够进一步提高摩擦材料的耐磨性能；
5、本发明利用渗碳碳纤维的柔韧性，通过超声波的作用在树脂浆料产生微泡，当声压或者声强到达一定程度时，微泡就会迅速膨胀，然后又突然闭合，微泡闭合的瞬间产生冲击波，使微泡周围产生约1012pa的压力，将碳化铌颗粒强制填充到碳纤维毯的空隙中，达到填隙的目的；
6、采用树脂浆料分散碳化铌填充处理，可以有效提高碳化铌颗粒悬浮性能，提高填充效率，当树脂高温炭化后形成的活性炭将碳化铌颗粒包裹，在渗硅过程中与硅蒸汽反应形成碳化硅，生成碳化硅将碳化铌颗粒牢固地结合在一起；
7、由于渗入的金属硅熔点较低为1420℃左右，摩擦材料工作面的温度瞬时可达近2000℃，将在金属硅氮化生成氮化硅，形成微孔结构的摩擦材料，可以大幅度提高摩擦材料工作面的耐受温度，提高摩擦材料的使用寿命。
具体实施方式
实施例1
（1）将密度为1.8g/cm3石墨化的碳纤维毯在900℃温度下通入丙烷气和氮气的混合气体，丙烷气:氮气的的摩尔比为1:4，流量控制在50ml/min，渗碳处理24小时获得渗碳碳纤维毯；
（2）将上述渗碳碳纤维毯浸入粒度小于0.3μm含量为5%的碳化铌树脂浆料里，置于超声波清洗器中填充碳化铌处理50分钟，取出干燥后制得填充碳化铌碳纤维毯，树脂浆料为含酚醛树脂5%的乙醇溶液；
（3）将上述填充碳化铌碳纤维毯在900℃温度下通入三氯甲基硅烷气、氢气和氩气的混合气体，三氯甲基硅烷气:氢气:氩气的摩尔比为1:5:5，流量控制在50ml/min，沉积碳化硅处理24小时获得沉积碳化硅碳纤维毯；
（4）将上述沉积碳化硅碳纤维毯埋入渗硅料里，在真空气氛下1500℃的温度下渗硅5小时制得渗硅碳纤维毯，其中，渗硅料为硅粉30%和直径为0.5mm炭粒70%外加5%浓度为0.2%的聚乙烯醇水溶液均匀混合后干燥制得；
（5）将上述渗硅碳纤维毯在1700℃的温度下氮化处理10小时制得碳化铌碳化硅-碳纤维摩擦材料。
实施例2
（1）将密度为0.8g/cm3石墨化的碳纤维毯在1000℃温度下通入丙烷气和氮气的混合气体，丙烷气:氮气的的摩尔比为1:5，流量控制在350ml/min，渗碳处理18小时获得渗碳碳纤维毯；
（2）将上述渗碳碳纤维毯浸入粒度小于0.3μm含量为12%的碳化铌树脂浆料里，置于超声波清洗器中填充碳化铌处理40分钟，取出干燥后制得填充碳化铌碳纤维毯，树脂浆料为含酚醛树脂12%的乙醇溶液；
（3）将上述填充碳化铌碳纤维毯在1000℃温度下通入三氯甲基硅烷气、氢气和氩气的混合气体，三氯甲基硅烷气:氢气:氩气的摩尔比为1:4:4，流量控制在350ml/min，沉积碳化硅处理18小时获得沉积碳化硅碳纤维毯；
（4）将上述沉积碳化硅碳纤维毯埋入渗硅料里，在真空气氛下1650℃的温度下渗硅4小时制得渗硅碳纤维毯，其中，渗硅料为硅粉40%和直径为2mm炭粒60%外加10%浓度为0.4%的聚乙烯醇水溶液均匀混合后干燥制得；
（5）将上述渗硅碳纤维毯在1550℃的温度下氮化处理18小时制得碳化铌碳化硅-碳纤维摩擦材料。
实施例3
（1）将密度为0.1g/cm3石墨化的碳纤维毯在1100℃温度下通入丙烷气和氮气的混合气体，丙烷气:氮气的的摩尔比为1:6，流量控制在600ml/min，渗碳处理10小时获得渗碳碳纤维毯；
（2）将上述渗碳碳纤维毯浸入粒度小于0.3μm含量为20%的碳化铌树脂浆料里，置于超声波清洗器中填充碳化铌处理30分钟，取出干燥后制得填充碳化铌碳纤维毯，树脂浆料为含酚醛树脂20%的乙醇溶液；
（3）将上述填充碳化铌碳纤维毯在1100℃温度下通入三氯甲基硅烷气、氢气和氩气的混合气体，三氯甲基硅烷气:氢气:氩气的摩尔比为1:3:3，流量控制在600ml/min，沉积碳化硅处理10小时获得沉积碳化硅碳纤维毯；
（4）将上述沉积碳化硅碳纤维毯埋入渗硅料里，在真空气氛下1800℃的温度下渗硅3小时制得渗硅碳纤维毯，其中，渗硅料为硅粉50%和直径为3mm炭粒50%外加15%浓度为0.6%的聚乙烯醇水溶液均匀混合后干燥制得；
（5）将上述渗硅碳纤维毯在1350℃的温度下氮化处理24小时制得碳化铌碳化硅-碳纤维摩擦材料。

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1.树脂分散碳化铌碳化硅-碳纤维摩擦材料的制备方法，其特征在于，将密度为0.1~1.8g/cm3石墨化的碳纤维毯进行渗碳处理后进行树脂分散碳化铌填充处理，再进行沉积碳化硅处理，再进行埋入渗硅处理，然后在氮气气氛中氮化处理制得树脂分散碳化铌碳化硅-碳纤维摩擦材料，具体步骤如下：
（1）将密度为0.1~1.8g/cm3石墨化的碳纤维毯在900~1100℃温度下通入丙烷气和氮气的混合气体，丙烷气:氮气的摩尔比为1:4~6，流量控制在50~600ml/min，渗碳处理10~24小时获得渗碳碳纤维毯；
（2）将上述渗碳碳纤维毯浸入粒度小于0.3μm含量为5~20%碳化铌的树脂浆料里，置于超声波清洗器中填充碳化铌处理30~50分钟，取出干燥后制得填充碳化铌碳纤维毯，其中树脂浆料为含酚醛树脂5~20%的乙醇溶液；
（3）将上述填充碳化铌碳纤维毯在900~1100℃温度下通入三氯甲基硅烷气、氢气和氩气的混合气体，沉积碳化硅处理10~24小时获得沉积碳化硅碳纤维毯，其中，三氯甲基硅烷气:氢气:氩气的摩尔比为1:3~5:3~5，流量为50~600ml/min；
（4）将上述沉积碳化硅碳纤维毯埋入渗硅料里，在真空气氛下1500~1800℃的温度下渗硅处理3~5小时制得渗硅碳纤维毯，其中，渗硅料为硅粉30~50%和直径为0.5~3mm炭粒50~70%的混合物外加5~15%浓度为0.2~0.6%聚乙烯醇水溶液均匀混合干燥后制得；
（5）将上述渗硅碳纤维毯在1350~1700℃的温度下氮化处理10~24小时制得树脂分散碳化铌碳化硅-碳纤维摩擦材料。
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