CN107723645A - 一种可重复利用的轻量化制动盘及其制备方法 - Google Patents

一种可重复利用的轻量化制动盘及其制备方法 Download PDF

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CN107723645A
CN107723645A CN201710972650.6A CN201710972650A CN107723645A CN 107723645 A CN107723645 A CN 107723645A CN 201710972650 A CN201710972650 A CN 201710972650A CN 107723645 A CN107723645 A CN 107723645A
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brake disc
matrix
repeatable
transition zone
face coat
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吴佩芳
释加才让
王灿
党纵
党一纵
范叶明
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Beijing Tianyishangjia New Material Co Ltd
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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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    • C23C4/134—Plasma spraying
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Abstract

本发明属于汽车/高铁配件技术领域，具体涉及一种可重复利用的轻量化制动盘及其制备方法。本发明提供的制动盘包括基体和表面涂层，所述表面涂层由氧化锆、氧化铝、碳化铬或者碳化钨‑12％钴制成，在基体与表面涂层之间设有过渡层，所述过渡层选用Al与Ni、Cr和Y中的一种或几种形成的合金层和/或表面涂层所用材料与金属的混合物形成的混合层。本发明提供的制动盘的制备方法为：通过铸造得到制动盘基体，然后对基体进行清洗、粗化，然后依次制备过渡层和表面涂层。本发明提供的制动盘基体不易变形、涂层与基体之间结合强度高、涂层不易脱落。

Description

一种可重复利用的轻量化制动盘及其制备方法
技术领域
本发明属于汽车/高铁配件技术领域，具体涉及一种可重复利用的轻量化制动盘及其制备方法。
背景技术
随着当前能源消耗及对大气造成的污染日益严峻，汽车尾气做为主要的污染源之一，减少二氧化碳排放是缓解气候变化非常重要的目标。根据汽车主机厂测试数据：汽车每减重10％，可节省10％的动能，减少4-10％的尾气排放，减少6-8％的燃油消耗量，百公里加速时间减少8％，刹车距离减少5％，使用寿命增加50％，汽车簧下重量减轻1kg，相当于簧上重量减轻9-10kg。对于现在的汽车而言，车身轻量化是一个趋势，车身重量的减轻，也应该伴随着簧下质量的减小，但是降低簧下质量相比减小车身重量要困难得多，在保证合理的几何悬挂设置和强度的要求下，通过使用更轻的材质来减小簧下质量不失为一计良策，刹车系统是簧下质量的重要组成部分，所以对刹车系统中的制动盘进行轻量化设计具有非常大的意义。
此外，中国高铁的运营成本主要包括：建设费用、运营费用、车辆折旧和维护及电力消耗。制动盘的寿命增加可大大降低车辆维护费用，制动摩擦副的轻量化可大大降低电力费用。以一列拥有8节编组的京沪高铁列车为例，其每100公里耗电1600KWh，则跑完京沪全程总耗电20928KWh。相当于要消耗约2.6吨煤，所以，高铁运营所消耗的能源也是非常庞大的。做为簧下重量的高铁制动盘重量减轻对于节能环保具有非常重要的意义。
为此，中国专利CN204852099U公开一种汽车制动盘，包括制动盘本体，所述的制动盘本体为铝合金制动盘本体，所述的铝合金制动盘本体的两个工作面上分别复合有一层耐磨层，其制动盘本体由铝合金制成，铝合金密度低，可大幅减轻制动盘的重量，与同等尺寸型号的传统铸铁制动盘相比，该技术提供的制动盘可减重50％以上，在铝合金制动盘基体上复合有一层耐磨层来提高制动盘的耐磨性。但由于该耐磨层隔热性能有限，频繁制动使得耐磨层温度极剧升高，导致铝合金基体产生热膨胀，而由于耐磨层与基体热膨胀系数不匹配影响两者的结合强度，使得耐磨层易脱落；更严重的是，高温导致铝合金基体发生软化造成刹车失灵，影响行车安全，且制动盘基体发生软化变形后不能重复利用。
发明内容
因此，本发明要解决的技术问题在于克服现有技术中，高温下制动盘铝合金基体易软化、涂层与基体之间结合强度不高、涂层易脱落的缺陷，从而提供一种可重复利用的轻量化制动盘及其制备方法。
为解决上述技术问题，本发明采用如下技术方案：
一种可重复利用的轻量化制动盘，包括基体和表面涂层，并在基体和表面涂层之间设有过渡层，所述过渡层选用膨胀系数介于基体与表面涂层之间的材料。
所述过渡层是为进一步缓解热应力，提高结合强度及涂层寿命设计，过渡层厚度及材质需根据涂层厚度及材质进行设计，优选的，所述过渡层包括Al与Ni、Cr和Y中的一种或几种形成的合金层。
进一步地，所述合金层中Al的用量6-15wt％。
进一步地，所述过渡层还包括表面涂层所用材料与金属的混合物形成的混合层。
进一步地，所述混合层中金属的用量为混合层质量的20-40wt％。
进一步地，所述过渡层包括相同或不同的若干合金层。
进一步地，所述过渡层包括相同或不同的若干混合层。
进一步地，所述表面涂层由氧化锆、氧化铝、碳化铬或者碳化钨与12wt％钴的混合物(即表面涂层中包括88wt％的碳化钨和12wt％的金属钴)制成。表面涂层需起到隔热、耐磨的作用。
所述基体为比铸铁轻的合金材料，优选的，所述基体为铝或铝合金。
一种制备上述可重复利用的轻量化制动盘的方法，包括，通过铸造得到制动盘基体，然后对基体进行清洗、粗化，然后依次制备过渡层和表面涂层。
进一步地，所述过渡层通过超音速喷涂、超音速等离子喷涂或电弧喷涂等工艺制得。所述表面涂层采用等离子喷涂、超音速等离子喷涂、超音速火焰喷涂、爆炸喷涂或微弧氧化等工艺实现。本发明提供的制动盘不仅适用汽车领域，在高铁上也一样适用。
附图说明
为了更清楚地说明本发明具体实施方式或现有技术中的技术方案，下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施方式，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1制动盘结构主视图；
图2图1中A部位放大示意图；
图3制动盘俯视图。
附图标记，1-基体，2-过渡层，3-表面涂层。
本发明技术方案，具有如下优点：
1.本发明提供的制动盘，在基体与表面涂层之间增设过渡层，可满足实现制动所需要的力学性能要求及热学性能要求，能够解决表面涂层与基体之间结合强度不高、涂层易脱落的技术问题，过渡层选用Al与Ni、Cr和Y中的一种或几种形成的合金层和/或表面涂层所用材料与金属的混合物形成的混合层，可以有效的降低由于表面涂层与基体热膨胀系数差异大产生的热应力，减缓微裂纹增生及裂纹扩展，从而有效的提高表面涂层热疲劳寿命。
2.本发明提供的制动盘，设有表面涂层，表面涂层由氧化锆、氧化铝、碳化铬或者碳化钨与钴的混合物制成，可以有效隔绝紧急制动过程中产生的热量，防止低熔点铝合金基体变形，表面涂层还具有较高的硬度，具有比铝合金基体更高的耐磨性能。
3.本发明提供的制动盘，采用铝或铝合金代替铸铁做为制动盘基体，减重50％以上；在铝/铝合金基体表面制备表面涂层，维持铝合金的力学性能，并起耐磨作用，可满足SAEJ2522要求的摩擦磨损性能。
4.本发明提供的制动盘，表面涂层与基体结合强度高达40-80MPa；隔热涂层可在10s内，将铝/铝合金基体温度降低200-800℃。
5.本发明提供的制动盘，制动盘达到寿命，可用机加工方式将涂层材料去除，对基体进行清洗粗化后，重复上述工艺，可实现铝合金基体的重复利用，可实现再加工，节约资源及成本。
具体实施方式
本发明实施例中，过渡层所用合金可以通过商够得到，也可以通过本领域的常规制备方法制备得到，为了便于说明，本发明实施例中过渡层选用的合金均为商够产品。
实施例1
一种可重复利用的轻量化制动盘，包括基体和表面涂层，然后在基体和表面涂层之间设有过渡层，所述过渡层为NiCrAlY合金(-140+325目，北矿新材料科技有限公司)，表面涂层为碳化钨-12％钴(即表面涂层中包括12wt％的金属钴)；所述基体材质为铝。其制备方法为：通过铸造得到制动盘铝基体，然后对基体进行清洗、粗化，以增加涂层与基体之间的结合强度，采用超音速等离子喷涂方法制备NiCrAlY合金(-140+325目，北矿新材料科技有限公司)过渡涂层，然后采用爆炸喷涂制备碳化钨-12％钴表面涂层。
实施例2
一种可重复利用的轻量化制动盘，包括基体和表面涂层，在基体和表面涂层之间设有过渡层，过渡层由三层构成分别为NiAl(北矿新材料科技有限公司)合金层、氧化锆40％Al混合层(即混合层由60wt％的氧化锆，40wt％的Al组成)、氧化锆20％Al(即混合层由80wt％的氧化锆，20wt％的Al组成)混合层，所述基体材质为铝，表面涂层为氧化锆。其制备方法为：通过铸造得到制动盘铝基体，然后对基体进行清洗、粗化，以增加涂层与基体之间的结合强度，然后在基体表面依次采用电弧喷涂法制备NiAl合金层、等离子喷涂制备氧化锆40％Al混合层、氧化锆20％Al混合层，采用微弧氧化法制备氧化锆表面涂层。
实施例3
一种可重复利用的轻量化制动盘，包括基体和表面涂层，在基体和表面涂层之间设有过渡层，所述过渡层为NiCrAlY(-140+325目，北矿新材料科技有限公司)合金层，过渡层由一层构成，所述基体材质为铝合金，表面涂层为碳化铬。其制备方法为：通过铸造得到制动盘铝合金基体，然后对基体进行清洗、粗化，以增加涂层与基体之间的结合强度，采用超音速喷涂方法制备NiCrAlY合金涂层，然后采用微弧氧化法制备碳化铬涂层。
实施例4
一种可重复利用的轻量化制动盘，包括基体和表面涂层，在基体和表面涂层之间设有过渡层，所述过渡层为NiAl(北矿新材料科技有限公司)合金层、氧化铝-20％Al混合层(即混合层由80wt％的氧化锆，20wt％的Al组成)，过渡层由两层构成，所述基体材质为铝，表面涂层为氧化铝。其制备方法为：通过铸造得到制动盘铝基体，然后对基体进行清洗、粗化，以增加涂层与基体之间的结合强度，采用电弧喷涂法制备NiAl涂层、等离子喷涂制备氧化铝-20％Al过渡层、氧化铝表面涂层。
实施例5
一种可重复利用的轻量化制动盘，包括基体和表面涂层，在基体和表面涂层之间设有过渡层，所述过渡层为NiAl合金层(北矿新材料科技有限公司)，所述基体材质为铝合金，表面涂层为氧化铝。其制备方法为：通过铸造得到制动盘铝合金基体，然后对基体进行清洗、粗化，以增加涂层与基体之间的结合强度，采用电弧喷涂方法制备NiAl合金涂层，然后采用微弧氧化法制备氧化铝涂层。
对比例1
一种轻量化制动盘，包括基体和表面涂层，所述基体材质为铝合金，表面涂层为TiC。其制备方法为：通过铸造得到碳化硅颗粒增强铝合金基体。
对比例2
一种轻量化制动盘，包括基体和表面涂层，所述基体材质为铝合金，表面涂层为碳化硅。其制备方法为：通过铸造得到制动盘铝合金基体，然后对基体进行清洗、粗化，以增加涂层与基体之间的结合强度，然后制备表面涂层。
实验例1
将本发明实施例1-5的制动盘和对比例1-2的制动盘的摩擦磨损性能在定速试验机上进行，试验结果请见下表：
表1摩擦磨损性能测试结果
实验例2
本发明提供的制动盘，表面涂层与基体结合强度高达40-80MPa。测试方法：热喷涂抗拉结合强度的测定，标准:GBT8642-2002。
轻量化制动盘拉伸结合强度试验结果如下表：
表2拉伸结合强度测试结果
实验例3
本发明提供的制动盘，过渡涂层可在10s内，将铝/铝合金基体温度降低200-800℃。隔热性能测试方法：在涂层单面热震性能测试仪器上进行，涂层一侧用氧乙炔火焰冲击至与实际工况相应的温度，模拟实际工况相应的环境，在规定的时间内，测试背侧基体的温度变化及达到的最高温度。二者差值即为所得数据。
表3隔热性能测试结果
显然，上述实施例仅仅是为清楚地说明所作的举例，而并非对实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引伸出的显而易见的变化或变动仍处于本发明创造的保护范围之中。

Claims (11)

1.一种可重复利用的轻量化制动盘，包括基体和表面涂层，其特征在于，在基体和表面涂层之间设有过渡层，所述过渡层选用膨胀系数介于基体与表面涂层之间的材料。
2.根据权利要求1所述的可重复利用的轻量化制动盘，其特征在于，所述过渡层包括Al与Ni、Cr和Y中的一种或几种形成的合金层。
3.根据权利要求2所述的可重复利用的轻量化制动盘，其特征在于，所述合金层中Al的用量为合金层质量的6-15wt％。
4.根据权利要求1-3任一所述的可重复利用的轻量化制动盘，其特征在于，所述过渡层还包括表面涂层所用材料与金属的混合物形成的混合层。
5.据权利要求4所述的可重复利用的轻量化制动盘，其特征在于，所述混合层中金属的用量为混合层质量的20-40wt％。
6.根据权利要求2-5任一所述的可重复利用的轻量化制动盘，其特征在于，所述过渡层包括相同或不同的若干合金层。
7.根据权利要求2-5任一所述的可重复利用的轻量化制动盘，其特征在于，所述过渡层包括相同或不同的若干混合层。
8.根据权利要求1-7任一所述的可重复利用的轻量化制动盘，其特征在于，所述表面涂层由氧化锆、氧化铝、碳化铬或者碳化钨-12wt％钴制成。
9.一种制备权利要求1-8任一项所述的可重复利用的轻量化制动盘的方法，包括，通过铸造得到制动盘基体，然后对基体进行清洗、粗化，然后依次制备过渡层和表面涂层。
10.根据权利要求9所述的制备所述可重复利用的轻量化制动盘的方法，其特征在于，所述过渡层通过超音速喷涂、超音速等离子喷涂或电弧喷涂工艺制得。
11.根据权利要求9所述的制备所述可重复利用的轻量化制动盘的方法，其特征在于，所述表面涂层的制备方法包括等离子喷涂、超音速等离子喷涂、超音速火焰喷涂、爆炸喷涂或微弧氧化工艺。
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