CN106103804A - 由铁合金组合物构成的制动盘涂层及其制造方法 - Google Patents
由铁合金组合物构成的制动盘涂层及其制造方法 Download PDFInfo
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- 239000000203 mixture Substances 0.000 title claims abstract description 33
- 229910000640 Fe alloy Inorganic materials 0.000 title claims abstract description 22
- 239000011248 coating agent Substances 0.000 title claims abstract description 22
- 238000000576 coating method Methods 0.000 title claims abstract description 22
- 238000000034 method Methods 0.000 title claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 title claims description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 10
- 239000002347 wear-protection layer Substances 0.000 claims description 19
- 239000010410 layer Substances 0.000 claims description 14
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- 229910052782 aluminium Inorganic materials 0.000 claims description 6
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
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- 238000007749 high velocity oxygen fuel spraying Methods 0.000 claims description 3
- 229910052758 niobium Inorganic materials 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 230000032683 aging Effects 0.000 claims description 2
- 239000004411 aluminium Substances 0.000 claims description 2
- 239000002245 particle Substances 0.000 claims description 2
- 239000000843 powder Substances 0.000 claims description 2
- 229910052720 vanadium Inorganic materials 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 13
- 229910045601 alloy Inorganic materials 0.000 description 12
- 239000000956 alloy Substances 0.000 description 12
- 229910052750 molybdenum Inorganic materials 0.000 description 8
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 7
- 239000011651 chromium Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 239000011733 molybdenum Substances 0.000 description 7
- 229910052759 nickel Inorganic materials 0.000 description 6
- 239000011572 manganese Substances 0.000 description 5
- 229910052799 carbon Inorganic materials 0.000 description 4
- 229910052804 chromium Inorganic materials 0.000 description 4
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- 229910052710 silicon Inorganic materials 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
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- 229910052748 manganese Inorganic materials 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 2
- 229910001021 Ferroalloy Inorganic materials 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 239000010962 carbon steel Substances 0.000 description 2
- 229910017052 cobalt Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
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- 229910001018 Cast iron Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910000531 Co alloy Inorganic materials 0.000 description 1
- 229910000604 Ferrochrome Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 230000003064 anti-oxidating effect Effects 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
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- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000010297 mechanical methods and process Methods 0.000 description 1
- 239000002905 metal composite material Substances 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
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- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- 238000005496 tempering Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
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- F16D65/00—Parts or details
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- F16D65/12—Discs; Drums for disc brakes
- F16D65/127—Discs; Drums for disc brakes characterised by properties of the disc surface; Discs lined with friction material
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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Abstract
本发明提供一种在制动盘制动面上的由铁合金组合物构成的磨损防护涂层，所述铁合金组合物具有0.5至2wt％的C、3至13wt％的Al以及将100wt％补足的剩余含量的Fe。本发明还提出一种涂布制动盘的方法。
Description
技术领域
本发明涉及一种作为制动盘上的磨损防护涂层的铁合金组合物、一种经磨损防护涂布的制动盘及其制造。
背景技术
由WO 03/104513 A1已知一种具有摩擦面的耐磨、经涂布、大体为金属性的汽车构件，如制动盘。该摩擦面由一个耐磨覆盖层制成，该覆盖层主要由钼构成，其中常见的组合物具有大于99％的钼。将一个接合层镀覆至这个构件的基本衬底，以便将覆盖层与基本衬底连接在一起。但钼处理的缺点是，钼的熔化温度较高，故其成本较高。
因而在WO 2007/04396 A1所提出的具有摩擦面的汽车构件中，耐磨覆盖层由含有50％至99％的钼的合金制成，其中剩余部分由以下元素中的至少一个构成：铝、硼、碳、铬、钴、镧、锰、镍、铌、氧、硅、钽、钨、钇。这个合金的液相线温度远低于钼，因此，该合金在热喷涂过程中会全部或几乎全部液化，从而有助于形成非多孔的覆盖层。其厚度约为25至600μm、优选为300μm。钼覆盖层与衬底间的连接层主要包括主含量镍和较小含量的铝。该连接层的厚度可以是0至100μm、优选约为50μm。
DE 10 2008 035 849 A1描述一种涂布钢制动盘的制动面的方法，其中通过热喷涂将耐磨涂层镀覆至粗化后的制动面。用来进行高速火焰喷涂的喷涂材料为由碳化钨与某种金属成分构成的陶瓷-金属复合材料，该金属成分由钴、镍构成或者由钴合金或镍合金构成。在电弧喷涂法中，可以往钢制动盘的制动面镀覆一个涂层，其由Fe 18Cr 8Ni 2Mn、Fe13Cr 0.5Si或者由合金碳钢构成，该合金碳钢包含约0.35％的碳含量以及形式为Si、Ni、Mn、P(微量)和硫(微量)的更多合金成分。
EP 1 336 054 B1描述一种制动盘和一种制造这种制动盘的方法。由铸铁材料(如碳含量为3.7％-4.0％的灰铸铁)构成的制动盘，在至少一个轴向摩擦面上具有抗氧化且耐磨的金属性非陶瓷注塑涂层，其由在结构中具有碳化物和氧化物的硬质金属(如非合金或合金的钢)构成。可以通过火焰喷涂、电弧喷涂或等离子喷涂来产生注塑涂层。所用钢合金可以含有Cr，其在涂层中的含量可以是10％至20％。该涂层钢的组合物具有16％的Cr；0.44％的Ni；0.43％的Mn；1.01％的Mo和0.36％的C。
发明内容
有鉴于以上现有技术，本发明的目的是提供一种用于制动盘的制动面的改进型磨损防护涂层。
本发明用以达成上述目的的解决方案为具有权利要求1的特征的一种位于制动盘上的磨损防护涂层。
本发明的另一目的是提供一种制动盘，其摩擦面将较高的硬度与较强的耐磨性相结合，从而在制动时减轻微尘形成，本发明用以达成上述目的的解决方案为具有权利要求6的特征的一种制动盘。
所述合金组合物和所述方法的改良方案参阅从属权利要求。
一种用于在制动盘的制动面即摩擦面上形成耐磨的磨损防护层的本发明的铁合金组合物，具有0.5至2wt％的C和3至13wt％的Al和将100wt％补足的剩余含量的Fe，该剩余含量包含不可避免的微量杂质。利用制动盘上的由这种合金组合物制成的磨损防护层，便能减轻制动盘磨损。所述磨损防护层为制动盘在摩擦面的区域内的最上面的材料层。布置在所述磨损防护层下方的制动盘可以由多个材料层构成，例如由基本材料与由不同材料制成的附着层或防腐层构成。所述制动盘为轻金属或铝合金制动盘时，由这种组合物构成的涂层能够大幅减小制动盘重量，因为该制动盘的基体可以设计得较细。
另一优选铁合金组合物具有0.5至2wt％的C和3至13wt％的Al，还具有0.5至5wt％的Cr和/或0.05至0.5wt％的Si。Cr和Si的这个含量主要有利于在涂层合金中形成硬质相。所述剩余含量为在钢中的包含常见微量杂质的Fe。这种组合物的优点是，仅使用易于获得的廉价合金元素。针对性地避免使用较为昂贵的Mo或Ni。
为增强该组合物的可变形性，前述铁合金组合物还可以具有0.5至5wt％的Mn以及(作为替代或补充方案)0.5至5wt％的Ni。通过Ni添加来增强合金基质的延展性。
所述铁合金组合物还可以具有各占0.1至3wt％的硬质材料形成剂，如W、V、Nb、B。
另一优选铁合金组合物具有0.8至1.2wt％的C、6至8wt％的Al、1.5至2.5wt％的Cr、0.1至0.3wt％的Si和将100wt％补足的剩余含量的Fe，该剩余含量包含不可避免的微量杂质。
在迄今为止的方案中，制动盘系列会承受严重磨损并在制动衬片上产生制动微尘，其会以影响视觉的方式沉积在轮辋上且难以去除，与此不同，由所述组合物制成的磨损防护层基本上永久性地具有耐磨效果。通过增强耐磨性便能在制动时减轻微尘形成。此外，用本发明的铁合金组合物所涂布的制动盘在制动效果保持不变的同时还大幅延长了使用寿命。
具有0.8至1.2wt％的C、6至8wt％的Al、1.5至2.5wt％的Cr、0.1至0.3wt％的Si和将100wt％补足的剩余含量的Fe的所述优选铁合金组合物，还可以具有1.8至2.2wt％的Mn以增强可变形性以及/或者1.8至2.2wt％的Ni以增强延展性。
这样就能使用所述铁合金组合物来在制动盘制动面上形成磨损防护层，其中通过热喷涂将所述铁合金组合物镀覆至所述制动面。
所述热喷涂的铁合金主要可以具有以下相：α-Fe(Al、Si、Mn)、Fe4-xAlxCy和(FeCr)3C。其中涉及的是较高含量的耐磨性极强的硬质相。元素Al及其在涂层中的化合物具有极佳的抗氧化性，从而实现极强的防腐性。高温下产生于制动过程中的氧化铝防止腐蚀范围扩大到层。
所述合金组合物的膨胀系数处于灰铸铁的水平。这样就在将廉价的灰铸铁用作制动盘衬底或基体的情况下，减小了热应力。
根据本发明，由铝或铝合金或者由灰铸铁构成的制动盘具有由本发明的铁合金组合物构成的磨损防护层。通过这种方式制成的制动盘的特点是，耐磨性较强，因而微尘形成较轻，且在抗氧化性与防腐性较高的同时延长了使用寿命。视需要也可以在所述制动盘的基本材料与所述磨损防护层之间镀覆中间层。该中间层指的是附着层或防腐层。优选采用Ni或Ni合金为该中间层的材料。
一种制造用磨损防护层涂布的制动盘的方法，首先是制造制动盘本体，随后对所述待涂布的制动面进行粗化处理，以增强而后喷涂的防护层在所述制动盘本体上的附着度。借助热喷涂法将由本发明的铁合金组合物构成的磨损防护层镀覆至所述粗化后的制动面后，对所述磨损防护层进行热和/或机械的后处理，以便增强所述磨损防护层的延展性和密封性。视需要也可以在所述制动盘的基本材料与所述磨损防护层之间镀覆中间层。该中间层指的是附着层或防腐层。特别是在采用Ni合金的情况下，可以通过电镀或者以喷涂层的形式涂覆所述中间层。
所述热和/或机械的后处理可指在800至950°范围内的高温条件下、优选在850至900°的温度条件下，对所镀覆的涂层进行热机械的后处理，如锻打或滚压。作为替代或补充方案，也可以随后在850至950°范围内、优选在约900°的温度条件下，实施时长为在0.5至3小时之间、优选1小时的时效处理(Verlagerung)，以便(进一步)增强延展性，因为通过这个回火步骤来对较脆的硬质相进行倒圆/成型处理。
可以廉价地用灰铸铁或者出于轻型化考虑而用铸铝制造所述制动盘本体。为在涂布前对制动面即摩擦面进行粗化，优选可以采用机械法，例如粒子束(如喷砂)、高压喷水或者使用具有优选也产生底切的规定切削刃的切割工具，以便随后喷涂的涂层与制动盘本体紧密结合在一起，从而进一步增强所述磨损防护层的附着度。
所述热喷涂法选自多种工艺，如大气等离子喷涂、火焰喷涂、高速火焰喷涂或电弧线材喷涂，其中在所述铁合金组合物实施为粉末的情况下，优选可以采用大气等离子喷涂。但在所述铁合金组合物实施为线材的情况下，考虑到喷涂层所能达到的均匀度以及成本，优选采用电弧线材喷涂。
Claims (9)
1.一种在制动盘制动面上的由铁合金组合物构成的磨损防护层，
其特征在于，
所述组合物具有
0.5至2wt％的C，
3至13wt％的Al以及
将100wt％补足的剩余含量的Fe和就钢而言常见的微量杂质。
2.根据权利要求1所述的磨损防护层，
其特征在于，
所述组合物还具有
0.5至5wt％的Cr和/或
0.05至0.5wt％的Si。
3.根据权利要求1或2所述的磨损防护层，
其特征在于，
所述组合物还具有
0.5至5wt％的Mn和/或
0.5至5wt％的Ni和/或
各占0.1至3wt％的W、V、Nb和/或B。
4.根据权利要求1至3中至少一项所述的铁合金组合物，
其特征在于，
所述组合物具有
0.8至1.2wt％的C，
6至8wt％的Al，
1.5至2.5wt％的Cr，
0.1至0.3wt％的Si。
5.根据权利要求1至4中至少一项所述的铁合金组合物，
其特征在于，
所述组合物还具有
1.5至2.5wt％的Mn和/或
1.5至2.5wt％的Ni。
6.一种制动盘，其至少一个制动面涂布有根据权利要求1至5中至少一项所述的磨损防护层，
其特征在于，
在制动盘本体与所述磨损防护层之间设有特别是基于Ni合金的中间层。
7.一种制造制动盘的方法，所述制动盘的至少一个制动面涂布有磨损防护层，
所述方法包括以下步骤，
-制造制动盘本体，
-对待涂布的制动面进行粗化处理，
-借助热喷涂法将根据权利要求1至5中至少一项所述的由铁合金组合物构成的磨损防护层镀覆至粗化后的制动面，
-对所述磨损防护层进行热和/或机械的后处理，以便增强延展性。
8.根据权利要求7所述的方法，
其中，
所述热和/或机械的后处理包括：
-优选地，在800至950°范围内、优选在850至900°范围内的温度条件下，对所述涂层进行锻打或滚压，以及/或者
-随后在850至950°范围内、优选在900°的温度条件下，进行时长为0.5至3小时、优选1小时的时效处理。
9.根据权利要求7或8所述的方法，
其中，
-用灰铸铁或铸铝制造所述制动盘本体，
-借助粒子束、高压喷水或者借助切割工具以产生底切的方式来实施粗化；
-所述热喷涂法选自大气等离子喷涂(APS)、火焰喷涂、高速火焰喷涂或电弧线材喷涂这些工艺，其中在所述铁合金组合物实施为粉末的情况下优选采用大气等离子喷涂，在所述铁合金组合物实施为线材的情况下优选采用电弧线材喷涂。
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| JP2017514992A (ja) | 2017-06-08 |
| EP3117025B1 (de) | 2018-10-24 |
| JP6254715B2 (ja) | 2017-12-27 |
| US10288136B2 (en) | 2019-05-14 |
| WO2015135639A1 (de) | 2015-09-17 |
| PL3117025T3 (pl) | 2019-03-29 |
| EP3117025A1 (de) | 2017-01-18 |
| US20170016497A1 (en) | 2017-01-19 |
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