CN106083048A - 一种汽车碳陶刹车盘的生产工艺 - Google Patents

一种汽车碳陶刹车盘的生产工艺 Download PDF

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CN106083048A
CN106083048A CN201610420803.1A CN201610420803A CN106083048A CN 106083048 A CN106083048 A CN 106083048A CN 201610420803 A CN201610420803 A CN 201610420803A CN 106083048 A CN106083048 A CN 106083048A
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batch mixing
brake disc
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李孙德
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Ma'anshan Sanchuan Machinery Manufacturing Co Ltd
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Abstract

本发明公开了一种汽车碳陶刹车盘的生产工艺，涉及汽车零部件生产工艺领域，包括原材料准备、混料一和混料二准备、单独加热处理、混料处理、二次混料处理和搅拌和真空烧结处理六个工艺过程，本发明利用两种性质相反的分散剂分别改性微硅粉和石墨粉，可以更好地使碳与硅的相互包覆，并通过两次球磨处理，使混合物混合效果更好，烧结之后生成的碳陶微球性能更好，通过该材料生产的汽车刹车盘摩擦系数高、耐久性较好、耐高温性能强，值得推广。

Description

一种汽车碳陶刹车盘的生产工艺
技术领域
本发明涉及汽车零部件生产工艺领域，具体涉及一种汽车碳陶刹车盘的生产工艺。
背景技术
碳陶复合刹车材料(以下简称碳陶)，是以高强度碳纤维为增强体，以热解碳、碳化硅为基体的两相或多相结合而成的一种新型复合材料，该材料集粉末冶金刹车材料和C/C刹车材料的优点于一体，并有效地克服了上述两种材料的缺点，具有重量轻、比强度高、比热大、摩擦性能稳定、机械性能稳定等优点，尤其是冲击韧性高，耐海水、盐雾腐蚀能力强，碳陶复合材料的制备方法主要有：1、热压烧结法，2、化学气相渗透，3、聚合物先驱体浸渗热解等，但是现有的技术中刹车盘上使用的碳陶复合材料仍然存在着摩擦系数不高、耐久性不好、耐高温性能不强的问题。
发明内容
本发明所要解决的问题是提供一种，性能更优、装配质量更高且生产工艺简单的汽车碳陶刹车盘的生产工艺。
为了实现上述目的，本发明采取的技术方案为：所提供的一种汽车碳陶刹车盘的生产工艺，其特征在于，包括下述工艺步骤：
(1)原材料准备：该汽车陶瓷刹车片的底料原材料包括如下质量分数：微硅粉20％-30％、环氧树脂4％-8％、200号溶剂油60％-70％、聚乙烯亚胺4％-8％；
(2)混料一和混料二准备：混料一原材料包括如下质量分数：石墨粒60％-70％、醇酸树脂10％-15％、其余为聚甲基丙烯酸铵，混料二原材料包括如下质量分数：酚醛树脂、氧化铝纤维、玻璃纤维、氧化铝、碳化硅、煅烧石油焦碳、天然橡胶、钛酸钾晶；
(3)单独加热处理：将底料和混料一分别放入加热炉中升温，升温时间为20min以上，升温结束后进行空冷至室温；
(4)混料处理：将得到的底料和混料一进行混合，并通过烘干机进行烘干，烘干温度为120℃-130℃，再通过球磨机对其进行球磨处理，处理时长为30min；
(5)二次混料处理：将混料处理得到的混合物与混料二进行均匀混合，并并通过球磨机对其进行球磨处理。
(6)真空烧结处理：将得到的混合物在真空烧结炉中进行真空烧结，烧结温度为1400℃以上，时长为4h-5h。
优选的，所述步骤(1)中微硅粉的平均粒径范围是200μm-300μm。
优选的，所述步骤(2)中混料二中各个质量分数重量所占比重分别为酚醛树脂15％-20％、氧化铝纤维10％-15％、玻璃纤维5％-10％、氧化铝5％-10％、碳化硅15％-20％、煅烧石油焦碳5％-10％、天然橡胶10％-15％、其余为钛酸钾晶。
优选的，所述步骤(4)中球磨机具体为一种圆锥形陶瓷球磨机，烘干处理的时长为2h-3h。
优选的，所述步骤(5)中球磨处理的时长为1h-1.5h。
优选的，所述步骤(6)中烧结时长为4h-5h。
采用本发明的技术方案，本发明利用两种性质相反的分散剂分别改性微硅粉和石墨粉，可以更好地使碳与硅的相互包覆，并通过两次球磨处理，使混合物混合效果更好，烧结之后生成的碳陶微球性能更好，通过该材料生产的汽车刹车盘摩擦系数高、耐久性较好、耐高温性能强，值得推广。
附图说明
图1为本发明所述的一种汽车碳陶刹车盘的生产工艺的流程图。
具体实施方式
为使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解，下面结合具体实施方式，进一步阐述本发明。
实施例1：
如图1所示，本实施例的一种汽车碳陶刹车盘的生产工艺，其特征在于，包括下述工艺步骤：
(1)底料原材料准备：该汽车陶瓷刹车片的底料原材料包括如下质量分数：微硅粉20％、环氧树脂7％、200号溶剂油65％、聚乙烯亚胺8％，其中微硅粉的平均粒径范围是250μm；
(2)混料一和混料二准备：混料一原材料包括如下质量分数：石墨粒65％、醇酸树脂15％、其余为聚甲基丙烯酸铵，混料二原材料包括如下质量分数：酚醛树脂、氧化铝纤维、玻璃纤维、氧化铝、碳化硅、煅烧石油焦碳、天然橡胶、钛酸钾晶，其中混料二中各个质量分数重量所占比重分别为酚醛树脂15％、氧化铝纤维15％、玻璃纤维10％、氧化铝5％、碳化硅20％、煅烧石油焦碳5％、天然橡胶10％、其余为钛酸钾晶；
(3)单独加热处理：将底料和混料一分别放入加热炉中升温，升温时间为20min，升温结束后进行空冷至室温；
(4)混料处理：将得到的底料和混料一进行混合，并通过烘干机进行烘干，烘干温度为120℃，再通过球磨机对其进行球磨处理，处理时长为30min，其中球磨机具体为一种圆锥形陶瓷球磨机，烘干处理的时长为2h-3h；
(5)二次混料处理：将混料处理得到的混合物与混料二进行均匀混合，并并通过球磨机对其进行球磨处理，其中球磨处理的时长为1h。
(6)真空烧结处理：将得到的混合物在真空烧结炉中进行真空烧结，烧结温度为1400℃，其中烧结温度为1400℃，时长为4h。
实施例2：其余与实施例1相同，不同之处在于所述步骤(1)中微硅粉的平均粒径范围是250μm，所述步骤(2)中混料二中各个质量分数重量所占比重分别为酚醛树脂15％、氧化铝纤维10％、玻璃纤维5％、氧化铝5％、碳化硅20％、煅烧石油焦碳10％、天然橡胶15％、其余为钛酸钾晶，所述步骤(4)中烘干处理的温度为125℃，时长为2.5h，所述步骤(5)中球磨处理的时长为1h，所述步骤(6)中烧结温度为1500℃，时长为4.5h。
实施例3：其余与实施例1相同，不同之处在于所述步骤(1)中微硅粉的平均粒径范围是300μm，所述步骤(2)中混料二中各个质量分数重量所占比重分别为酚醛树脂20％、氧化铝纤维15％、玻璃纤维10％、氧化铝10％、碳化硅15％、煅烧石油焦碳5％、天然橡胶10％、其余为钛酸钾晶，所述步骤(4)中烘干处理的温度为130℃，时长为3h，所述步骤(5)中球磨处理的时长为1.5h，所述步骤(6)中烧结温度为1600℃，时长为5h。
经过以上工艺步骤后，取出碳陶刹车盘样品，得到以下数据：
由以上数据可知，制备出的碳陶刹车盘摩擦系数和密度数值稳定,磨损率稳定且较低，断裂韧性均于5.0MPa/m1/2左右，寿命较长，性能相对较好，可以适用于汽车中长时间使用，且制备工艺简单，易实现大规模生产。
显然本发明具体实现并不受上述方式的限制，只要采用了本发明的方法构思和技术方案进行的各种非实质性的改进，或未经改进将本发明的构思和技术方案直接应用于其它场合的，均在本发明的保护范围之内。

Claims (6)

1.一种汽车碳陶刹车盘的生产工艺，其特征在于，包括下述工艺步骤：
(1)原材料准备：该汽车陶瓷刹车片的底料原材料包括如下质量分数：微硅粉20％-30％、环氧树脂4％-8％、200号溶剂油60％-70％、聚乙烯亚胺4％-8％；
(2)混料一和混料二准备：混料一原材料包括如下质量分数：石墨粒60％-70％、醇酸树脂10％-15％、其余为聚甲基丙烯酸铵，混料二原材料包括如下质量分数：酚醛树脂、氧化铝纤维、玻璃纤维、氧化铝、碳化硅、煅烧石油焦碳、天然橡胶、钛酸钾晶；
(3)单独加热处理：将底料和混料一分别放入加热炉中升温，升温时间为20min以上，升温结束后进行空冷至室温；
(4)混料处理：将得到的底料和混料一进行混合，并通过烘干机进行烘干，烘干温度为120℃-130℃，再通过球磨机对其进行球磨处理，处理时长为30min；
(5)二次混料处理：将混料处理得到的混合物与混料二进行均匀混合，并并通过球磨机对其进行球磨处理。
(6)真空烧结处理：将得到的混合物在真空烧结炉中进行真空烧结，烧结温度为1400℃以上，时长为4h-5h。
2.根据权利要求1所述的一种汽车碳陶刹车盘的生产工艺，其特征在于：所述步骤(1)中微硅粉的平均粒径范围是200μm-300μm。
3.根据权利要求1所述的一种汽车碳陶刹车盘的生产工艺，其特征在于：所述步骤(2)中混料二中各个质量分数重量所占比重分别为酚醛树脂15％-20％、氧化铝纤维10％-15％、玻璃纤维5％-10％、氧化铝5％-10％、碳化硅15％-20％、煅烧石油焦碳5％-10％、天然橡胶10％-15％、其余为钛酸钾晶。
4.根据权利要求1所述的一种汽车碳陶刹车盘的生产工艺，其特征在于：所述步骤(4)中球磨机具体为一种圆锥形陶瓷球磨机，烘干处理的时长为2h-3h。
5.根据权利要求1所述的一种汽车碳陶刹车盘的生产工艺，其特征在于：所述步骤(5)中球磨处理的时长为1h-1.5h。
6.根据权利要求1所述的一种汽车碳陶刹车盘的生产工艺，其特征在于：所述步骤(6)中烧结时长为1400℃-1600℃。
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