CN107876730B - 耐磨材料、局部增强轻金属基复合材料及制备方法 - Google Patents
耐磨材料、局部增强轻金属基复合材料及制备方法 Download PDFInfo
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- CN107876730B CN107876730B CN201711113030.3A CN201711113030A CN107876730B CN 107876730 B CN107876730 B CN 107876730B CN 201711113030 A CN201711113030 A CN 201711113030A CN 107876730 B CN107876730 B CN 107876730B
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- 239000000463 material Substances 0.000 title claims abstract description 74
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 43
- 239000002184 metal Substances 0.000 title claims abstract description 43
- 239000002131 composite material Substances 0.000 title claims abstract description 36
- 238000002360 preparation method Methods 0.000 title claims abstract description 11
- 239000002245 particle Substances 0.000 claims abstract description 92
- 239000000835 fiber Substances 0.000 claims abstract description 83
- 239000000919 ceramic Substances 0.000 claims abstract description 45
- 239000003870 refractory metal Substances 0.000 claims abstract description 35
- 239000006260 foam Substances 0.000 claims abstract description 30
- 239000011159 matrix material Substances 0.000 claims abstract description 21
- 229910001092 metal group alloy Inorganic materials 0.000 claims abstract description 21
- 238000000034 method Methods 0.000 claims abstract description 14
- 238000005266 casting Methods 0.000 claims abstract description 8
- 150000001875 compounds Chemical class 0.000 claims abstract description 7
- 239000000203 mixture Substances 0.000 claims abstract description 5
- 239000000956 alloy Substances 0.000 claims description 20
- 229910045601 alloy Inorganic materials 0.000 claims description 19
- 229910000831 Steel Inorganic materials 0.000 claims description 15
- 239000010959 steel Substances 0.000 claims description 15
- 229910000838 Al alloy Inorganic materials 0.000 claims description 14
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 14
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 13
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 12
- 239000000853 adhesive Substances 0.000 claims description 12
- 230000001070 adhesive effect Effects 0.000 claims description 12
- 239000002893 slag Substances 0.000 claims description 12
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 10
- 239000000047 product Substances 0.000 claims description 9
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 9
- 239000002002 slurry Substances 0.000 claims description 9
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 7
- 230000002708 enhancing effect Effects 0.000 claims description 7
- 239000010439 graphite Substances 0.000 claims description 7
- 229910002804 graphite Inorganic materials 0.000 claims description 7
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 6
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 6
- 239000010949 copper Substances 0.000 claims description 6
- 229910052802 copper Inorganic materials 0.000 claims description 6
- 229910052742 iron Inorganic materials 0.000 claims description 6
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 6
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 5
- 239000010881 fly ash Substances 0.000 claims description 5
- 239000008187 granular material Substances 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 229910052759 nickel Inorganic materials 0.000 claims description 5
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 5
- 239000000843 powder Substances 0.000 claims description 5
- 239000000243 solution Substances 0.000 claims description 5
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 5
- 229910052582 BN Inorganic materials 0.000 claims description 4
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 4
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 4
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 claims description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 4
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 4
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 4
- 239000000292 calcium oxide Substances 0.000 claims description 4
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 4
- 239000004917 carbon fiber Substances 0.000 claims description 4
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 claims description 4
- 238000001035 drying Methods 0.000 claims description 4
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 4
- 229910052737 gold Inorganic materials 0.000 claims description 4
- 239000010931 gold Substances 0.000 claims description 4
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 claims description 4
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 4
- 239000000395 magnesium oxide Substances 0.000 claims description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 4
- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 claims description 4
- 239000010703 silicon Substances 0.000 claims description 4
- 229910052710 silicon Inorganic materials 0.000 claims description 4
- 239000010935 stainless steel Substances 0.000 claims description 4
- 229910001220 stainless steel Inorganic materials 0.000 claims description 4
- 210000002268 wool Anatomy 0.000 claims description 4
- 239000011787 zinc oxide Substances 0.000 claims description 4
- 229910052726 zirconium Inorganic materials 0.000 claims description 4
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 4
- 229910000906 Bronze Inorganic materials 0.000 claims description 3
- 239000002253 acid Substances 0.000 claims description 3
- 239000007864 aqueous solution Substances 0.000 claims description 3
- 238000009954 braiding Methods 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 235000012239 silicon dioxide Nutrition 0.000 claims description 3
- 210000000988 bone and bone Anatomy 0.000 claims description 2
- 239000011265 semifinished product Substances 0.000 claims description 2
- 238000005245 sintering Methods 0.000 claims description 2
- 239000000758 substrate Substances 0.000 claims description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims 2
- 229910000952 Be alloy Inorganic materials 0.000 claims 1
- HMDDXIMCDZRSNE-UHFFFAOYSA-N [C].[Si] Chemical compound [C].[Si] HMDDXIMCDZRSNE-UHFFFAOYSA-N 0.000 claims 1
- 239000001913 cellulose Substances 0.000 claims 1
- 229920002678 cellulose Polymers 0.000 claims 1
- 239000004575 stone Substances 0.000 claims 1
- 238000005728 strengthening Methods 0.000 abstract description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 6
- 239000007788 liquid Substances 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 3
- 239000001768 carboxy methyl cellulose Substances 0.000 description 3
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 3
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 239000000178 monomer Substances 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 2
- 238000009716 squeeze casting Methods 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 241000790917 Dioxys <bee> Species 0.000 description 1
- 241001124569 Lycaenidae Species 0.000 description 1
- 229910001051 Magnalium Inorganic materials 0.000 description 1
- 241000219098 Parthenocissus Species 0.000 description 1
- 229910003978 SiClx Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- PZZYQPZGQPZBDN-UHFFFAOYSA-N aluminium silicate Chemical compound O=[Al]O[Si](=O)O[Al]=O PZZYQPZGQPZBDN-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 235000014987 copper Nutrition 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000003110 molding sand Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052573 porcelain Inorganic materials 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
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- B22D19/00—Casting in, on, or around objects which form part of the product
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- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
- B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
- B22F7/006—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part the porous part being obtained by foaming
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
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- F16D69/028—Compositions based on metals or inorganic oxides containing fibres
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Abstract
本发明耐磨材料的组成包括质量比为（10~60）：（1~30）：（10~70）的耐高温金属骨架材料、陶瓷纤维材料和陶瓷颗粒材料，耐高温金属骨架材料为泡沫金属或耐高温金属纤维，该耐磨材料耐磨性好、强韧性高，适用于对耐磨性、强韧性要求较高的场合，可局部复合于轻金属合金基体的表面，提高轻金属合金基体高温下的耐磨性和强韧性；本发明局部增强轻金属基复合材料，通过耐磨材料进行局部强化的轻金属合金基体，可制成重量轻、耐磨性好、导热性好的制动毂或制动盘，提高车辆安全性；本发明局部增强轻金属基复合材料的制备方法，通过挤压铸造工艺将耐磨层与轻金属合金基体冶金结合，确保复合材料的耐磨性和综合力学性能满足使用要求。
Description
技术领域
本发明涉及耐磨材料及局部增强金属基复合材料技术领域，具体是一种耐磨材料、利用该耐磨材料进行局部增强的轻金属基复合材料及该轻金属基复合材料的制备方法。
背景技术
耐磨材料是工业生产中的一种重要的基础材料，与现代化生产和生活密切相关。日常生活中最常见的耐磨机构是汽车制动毂和制动盘。制动毂和制动盘为汽车上关键的安全件，起摩擦制动作用，要求具有良好的耐磨性及综合力学性能。在行车过程中，制动毂或制动盘能否安全可靠地制动非常重要，若紧急情况下发生刹车失灵，将会造成安全事故，甚至造成车毁人亡大事故。因此，制动毂和制动盘是非常重要的安全件。历来，国内外的汽车制动毂和制动盘大多是用铸铁整体铸造而成，其耐磨性和力学性能好，铸造工艺成熟，可成形复杂通风孔，价格较低，适合大批量生产。但是铸铁制动毂和制动盘有下列不足处；1、铸铁密度高，密度达7.3g/cm2左右，因此制动毂和制动盘的重量较重，而制动毂和制动盘的重量属于非簧载重量，相当于3～5倍的簧载重量，无疑会明显增加车辆油耗，降低车辆机动性能，此外，相关部件拆装、维修较困难；2、铸铁的导热性较差，刹车时磨擦产生的热量散发慢，易造成刹车系统因温升过高而工作失灵。3、铸铁制动毂和制动盘一般用型砂铸造，铸件尺寸精度、表面光洁度差，内部缩松气孔不易控制，且铸造生产的劳动强度高，对环境污染较大。
发明内容
本发明所要解决的第一个技术问题是提供一种耐磨材料。
本发明所要解决的第二个技术问题是提供一种利用该耐磨材料进行局部增强的轻金属基复合材料。
本发明所要解决的第三个技术问题是提供一种轻金属基复合材料的制备方法。
本发明解决上述技术问题所采用的技术方案为：耐磨材料，该耐磨材料的组成包括质量比为(10～60)：(1～30)：(10～70)的耐高温金属骨架材料、陶瓷纤维材料和陶瓷颗粒材料，所述的耐高温金属骨架材料为泡沫金属或耐高温金属纤维，所述的耐高温金属纤维包括铁基合金纤维、镍基合金纤维、铜基合金纤维、不锈钢纤维、钢棉纤维、钛基合金纤维和钴基合金纤维中的一种或多种，所述的陶瓷纤维材料包括氧化铝纤维、硅酸铝纤维、二氧化硅纤维、氧化锆纤维、碳化硅纤维、石墨纤维和碳纤维中的一种或多种，所述的陶瓷颗粒材料包括粉煤灰颗粒、矿渣微粉颗粒、碳化硅颗粒、二氧化硅颗粒、氮化硼颗粒、锆英粉颗粒、棕刚玉颗粒、氧化锆颗粒、硅酸锆颗粒和氧化铬颗粒中的一种或多种。
作为优选，所述的陶瓷颗粒材料中混合有辅助增强颗粒，所述的辅助增强颗粒为石墨颗粒和/或钢渣颗粒，所述的钢渣颗粒为氧化铁颗粒、氧化锌颗粒、氧化钙颗粒、氧化镁颗粒、氧化铝颗粒和氧化钛颗粒中的一种或多种。
作为优选，所述的泡沫金属为泡沫铜、泡沫铁、泡沫镍或泡沫铁镍。
作为优选，所述的陶瓷纤维材料的直径为5～15μm、长度为0.8～2.8mm，所述的耐高温金属纤维的直径为0.01～2mm，所述的陶瓷颗粒材料的粒度为5～200μm、莫氏硬度为5～9，所述的泡沫金属的孔隙度为10～60ppi。
局部增强轻金属基复合材料，包括轻金属合金基体及局部复合于该轻金属合金基体表面的耐磨层，所述的轻金属合金基体为铝合金基体或镁合金基体，所述的耐磨层的组成包括质量比为(10～60)：(1～30)：(10～70)：(0.5～8)：(0.5～10)的耐高温金属骨架材料、陶瓷纤维材料、陶瓷颗粒材料、低温粘合剂和高温粘合剂；所述的耐高温金属骨架材料为泡沫金属或耐高温金属纤维，所述的耐高温金属纤维包括铁基合金纤维、镍基合金纤维、铜基合金纤维、不锈钢纤维、钢棉纤维、钛基合金纤维和钴基合金纤维中的一种或多种，所述的陶瓷纤维材料包括氧化铝纤维、硅酸铝纤维、二氧化硅纤维、氧化锆纤维、碳化硅纤维、石墨纤维和碳纤维中的一种或多种，所述的陶瓷颗粒材料包括粉煤灰颗粒、矿渣微粉颗粒、碳化硅颗粒、二氧化硅颗粒、氮化硼颗粒、锆英粉颗粒、棕刚玉颗粒、氧化锆颗粒、硅酸锆颗粒和氧化铬颗粒中的一种或多种，所述的低温粘合剂是浓度为3～20％的羧甲基纤维素水溶液，所述的高温粘合剂是浓度为10～60％的硅溶胶溶液。
作为优选，所述的陶瓷颗粒材料中混合有辅助增强颗粒，所述的辅助增强颗粒为石墨颗粒和/或钢渣颗粒，所述的钢渣颗粒为氧化铁颗粒、氧化锌颗粒、氧化钙颗粒、氧化镁颗粒、氧化铝颗粒和氧化钛颗粒中的一种或多种。
作为优选，所述的泡沫金属为泡沫铜、泡沫铁、泡沫镍或泡沫铁镍。
作为优选，所述的陶瓷纤维材料的直径为5～15μm、长度为0.8～2.8mm，所述的耐高温金属纤维的直径为0.01～2mm，所述的陶瓷颗粒材料的粒度为5～200μm、莫氏硬度为5～9，所述的泡沫金属的孔隙度为10～60ppi。
上述局部增强轻金属基复合材料的制备方法，包括以下步骤：按质量分数计，将1～30％的陶瓷纤维材料、10～70％的陶瓷颗粒材料、0.5～8％的低温粘合剂和0.5～10％的高温粘合剂，加入适量水均匀混合制成陶瓷浆料，再将该陶瓷浆料定量浇入预装有耐高温金属骨架的预制件模具中，加压20～30MPa，去水并压制成复合材料预制件半成品；然后将该复合材料预制件先在60～200℃温度下烘干处理10～20h，再在700～1000℃温度下烧结处理2.5～4h，得到复合材料预制件成品；最后采用挤压铸造工艺将该复合材料预制件成品复合于事先准备好的轻金属合金基体，使耐磨层预制件与轻金属合金基体冶金结合，即得到局部增强轻金属基复合材料。
作为优选，所述的耐高温金属骨架的制作过程为：将泡沫金属用机械加工的手段，加工出与所述的耐磨层的形状大小相匹配的板料，得到耐高温金属骨架，或者，将耐高温金属纤维经梳理、加工、编织、平铺至骨架预制件模具中并压实，得到耐高温金属骨架。
与现有技术相比，本发明的优点在于：
1、本发明公开的耐磨材料的组成包括质量比为(10～60)：(1～30)：(10～20)的耐高温金属骨架材料、陶瓷纤维材料和陶瓷颗粒材料，耐磨性好、强韧性高，适用于对耐磨性、强韧性要求较高的场合，可局部复合于轻金属合金基体的表面，提高轻金属合金基体高温下的耐磨性和强韧性；
2、本发明公开的局部增强轻金属基复合材料，通过本发明耐磨材料对轻金属合金基体进行有选择性的局部强化，在轻金属合金基体的表面形成耐磨层，以提高其在高温下的耐磨性和强韧性；此外，轻金属合金基体比重轻，将其制成汽车或火车等的制动毂或制动盘并在其工作面上复合本发明耐磨层后，相比于现有铸铁制动毂或制动盘，表面耐磨性可提高到现有铸铁制动毂或制动盘的4倍以上，并减轻一半以上重量，并且，铝镁等轻金属合金的导热性比铸铁好得多，可使制动毂(或制动盘)的工作温度降低近100℃；同时，由于减轻了车辆重量，尤其是簧上重量，因而可降低车辆油耗，还可减少汽车、火车等制动系统的原材料成本、加工成本及维护成本，改善车辆通过性能，缩短刹车距离，提高车辆安全性等；
3、本发明公开的局部增强轻金属基复合材料，可替代现有仅通过陶瓷增强的铝基复合材料，将其用挤压铸造工艺，做成大马力柴油机镶圈活塞，在保持原镶圈活塞的使用寿命前提下，可提高活塞的使用温度达50～100℃，从而可提高柴油机的输出功率，节约油耗，减少废气排放；
4、本发明公开的局部增强轻金属基复合材料，可取代现有镶钢套的均质铝合金材料，通过挤压铸造工艺，直接成形为带有本发明耐磨材料制成的复合材料耐磨环的履带车辆的镁合金负重轮，在保持原负重轮的耐磨性及使用寿命的前提下，可以减轻1/3负重轮的重量，并减少车辆震动和噪音；
5、本发明公开的局部增强轻金属基复合材料的制备方法，可操作性强。该制备方法通过挤压铸造工艺将耐磨层与轻金属合金基体冶金结合，在挤压铸造过程中轻金属合金液渗入多孔的预制件内形成复合材料，构成复合材料的耐磨层与轻金属合金基体冶金结合，确保局部增强轻金属基复合材料的耐磨性和综合力学性能满足使用要求。
附图说明
图1为实施例1制得的具有耐磨层的铝合金汽车制动盘的结构示意图；
图2为实施例2制得的具有耐磨层的镁合金卡车制动毂的结构示意图。
具体实施方式
以下结合附图实施例对本发明作进一步详细描述。
实施例1：制备具有耐磨层的铝合金汽车制动盘，该汽车制动盘由美国牌号A356的铸造铝合金制成，其尺寸为Φ288mm(外径)×44.6mm(厚度)，其耐磨层为尺寸为Φ288mm(外径)×184mm(内径)×3mm(厚度)的圆环。制备方法包括以下步骤：
(1)将孔隙度为10～60ppi的厚度为10mm的泡沫铜，机械加工成Φ288mm(外径)×184mm(内径)×10mm(厚度)，得到耐高温金属骨架，将耐高温金属骨架置于预制件模具中；
(2)按质量分数计，将10％的氧化铝纤维、5％的硅酸铝纤维和40％的粉煤灰颗粒、8％的碳化硅颗粒与3％的羧甲基纤维素水溶液(浓度为20％)和12％的硅熔胶溶液(浓度为50％)与适量水经均匀混合制成陶瓷浆料，再将该陶瓷浆料定量浇入预装有耐高温金属骨架的预制件模具中，先抽真空至1×10-2Pa，再加压20～30MPa，去水并压制成Φ288mm(外径)×184mm(内径)×10mm(厚度)的圆环，再在130℃温度下烘干处理10h、在850℃温度下烧结处理3h，得到预制件单体；
(3)取两个预制件单体，并将这两个预制件单体用六个泡沫铜制成的支撑筋连接，再放入挤压铸造模具的指定位置中，浇入液态的A356铝合金，合模加压，使液态铝合金在压力下渗入多孔的预制件中，并充填满挤压铸造模腔，制得铝合金汽车制动盘整体毛坯，其上下表面帶有耐磨层；
(4)将铝合金汽车制动盘整体毛坯经T6热处理和机械加工，得到实施例1的具有耐磨层的铝合金汽车制动盘成品，其结构示意图见图1。如图1所示的铝合金汽车制动盘，包括铝合金制动盘本体1，铝合金制动盘本体1的两个工作面上分别复合有一层耐磨层2，两层耐磨层2经六个支撑筋3上下相连，六个支撑单元3沿两层耐磨层2的周向间隔设置。
实施例2：制备具有耐磨层的镁合金卡车制动毂，该汽车制动毂由美国牌号AZ91D的铸造镁合金制成，其尺寸为Φ480mm(外径)×227mm(高度)，其耐磨层的尺寸为Φ420mm(外径)×180mm(高度)×7mm(筒壁厚度)。制备方法包括以下步骤：
(1)按质量分数计，将40％的直径为0.4～1mm的高强度钢纤维经梳理、编织，平铺于圆筒形的预制件模具内并压实，制成耐高温金属骨架并置于预制件模具的靠近内壁的部位，再将12％的硅酸铝纤维、41％的碳化硅颗粒与5％的羧甲基纤维素水溶液(浓度为20％)和10％的硅熔胶溶液(浓度为60％)与适量水经均匀混合制成陶瓷浆料，再将该陶瓷浆料定量浇入上述预装有耐高温金属骨架的预制件模具中，使预制件模具绕其中心轴旋转，使陶瓷浆料在离心力作用下浸入钢纤维的缝隙中，并甩掉部分水分，得到圆筒状的预制件毛坯，其尺寸为Φ420mm(内径)×180mm(高度)×12mm(筒壁厚度)；
(2)以制成圆筒状的预制件毛坯，该预制件成品的尺寸为Φ420mm(外径)×180mm(高度)×12mm(厚度)；然后将预制件毛坯先在100℃温度下烘干处理15h，再在800℃温度下烧结处理3h，得到预制件成品；
(3)将预制件成品放入挤压铸造模具的指定位置中，浇入液态的AZ91D镁合金，合模加压，使液态镁合金在压力下渗入多孔的预制件中，并充填满挤压铸造模腔，制得镁合金卡车制动毂毛坯，其内壁帶有耐磨层；
(4)将镁合金卡车制动毂毛坯经T6热处理和机械加工，得到实施例2的具有耐磨层的镁合金卡车制动毂成品，其结构示意图见图2。如图2所示的镁合金卡车制动毂，包括圆筒状的镁合金制动毂本体1、镁合金制动毂本体1的内壁复合有圆筒状的耐磨层2。
Claims (9)
1.耐磨材料，其特征在于：该耐磨材料的组成包括质量比为(10～60)：(1～30)：(10～70)的耐高温金属骨架材料、陶瓷纤维材料和陶瓷颗粒材料，所述的耐高温金属骨架材料为泡沫金属或耐高温金属纤维，所述的耐高温金属纤维包括铁基合金纤维、镍基合金纤维、铜基合金纤维、不锈钢纤维、钢棉纤维、钛基合金纤维和钴基合金纤维中的一种或多种，所述的陶瓷纤维材料包括氧化铝纤维、硅酸铝纤维、二氧化硅纤维、氧化锆纤维、碳化硅纤维、石墨纤维和碳纤维中的一种或多种，所述的陶瓷颗粒材料包括粉煤灰颗粒、矿渣微粉颗粒、碳化硅颗粒、二氧化硅颗粒、氮化硼颗粒、锆英粉颗粒、棕刚玉颗粒、氧化锆颗粒、硅酸锆颗粒和氧化铬颗粒中的一种或多种；所述的耐高温金属骨架的制作过程为：将泡沫金属用机械加工的手段，加工出与耐磨层的形状大小相匹配的板料，得到耐高温金属骨架，或者，将耐高温金属纤维经梳理、加工、编织、平铺至骨架预制件模具中并压实，得到耐高温金属骨架。
2.根据权利要求1所述的耐磨材料，其特征在于：所述的陶瓷颗粒材料中混合有辅助增强颗粒，所述的辅助增强颗粒为石墨颗粒和/或钢渣颗粒，所述的钢渣颗粒为氧化铁颗粒、氧化锌颗粒、氧化钙颗粒、氧化镁颗粒、氧化铝颗粒和氧化钛颗粒中的一种或多种。
3.根据权利要求1所述的耐磨材料，其特征在于：所述的泡沫金属为泡沫铜、泡沫铁、泡沫镍或泡沫铁镍。
4.根据权利要求1所述的耐磨材料，其特征在于：所述的陶瓷纤维材料的直径为5～15μm、长度为0.8～2.8mm，所述的耐高温金属纤维的直径为0.01～2mm，所述的陶瓷颗粒材料的粒度为5～200μm、莫氏硬度为5～9，所述的泡沫金属的孔隙度为10～60ppi。
5.局部增强轻金属基复合材料，其特征在于：包括轻金属合金基体及局部复合于该轻金属合金基体表面的耐磨层，所述的轻金属合金基体为铝合金基体或镁合金基体，所述的耐磨层的组成包括质量比为(10～60)：(1～30)：(10～70)：(0.5～8)：(0.5～10)的耐高温金属骨架材料、陶瓷纤维材料、陶瓷颗粒材料、低温粘合剂和高温粘合剂；所述的耐高温金属骨架材料为泡沫金属或耐高温金属纤维，所述的耐高温金属纤维包括铁基合金纤维、镍基合金纤维、铜基合金纤维、不锈钢纤维、钢棉纤维、钛基合金纤维和钴基合金纤维中的一种或多种，所述的陶瓷纤维材料包括氧化铝纤维、硅酸铝纤维、二氧化硅纤维、氧化锆纤维、碳化硅纤维、石墨纤维和碳纤维中的一种或多种，所述的陶瓷颗粒材料包括粉煤灰颗粒、矿渣微粉颗粒、碳化硅颗粒、二氧化硅颗粒、氮化硼颗粒、锆英粉颗粒、棕刚玉颗粒、氧化锆颗粒、硅酸锆颗粒和氧化铬颗粒中的一种或多种，所述的低温粘合剂是浓度为3～20％的羧甲基纤维素水溶液，所述的高温粘合剂是浓度为10～60％的硅溶胶溶液；所述的耐高温金属骨架的制作过程为：将泡沫金属用机械加工的手段，加工出与所述的耐磨层的形状大小相匹配的板料，得到耐高温金属骨架，或者，将耐高温金属纤维经梳理、加工、编织、平铺至骨架预制件模具中并压实，得到耐高温金属骨架。
6.根据权利要求5所述的局部增强轻金属基复合材料，其特征在于：所述的陶瓷颗粒材料中混合有辅助增强颗粒，所述的辅助增强颗粒为石墨颗粒和/或钢渣颗粒，所述的钢渣颗粒为氧化铁颗粒、氧化锌颗粒、氧化钙颗粒、氧化镁颗粒、氧化铝颗粒和氧化钛颗粒中的一种或多种。
7.根据权利要求5所述的局部增强轻金属基复合材料，其特征在于：所述的泡沫金属为泡沫铜、泡沫铁、泡沫镍或泡沫铁镍。
8.根据权利要求5所述的局部增强轻金属基复合材料，其特征在于：所述的陶瓷纤维材料的直径为5～15μm、长度为0.8～2.8mm，所述的耐高温金属纤维的直径为0.01～2mm，所述的陶瓷颗粒材料的粒度为5～200μm、莫氏硬度为5～9，所述的泡沫金属的孔隙度为10～60ppi。
9.权利要求5～8中任一项所述的局部增强轻金属基复合材料的制备方法，其特征在于包括以下步骤：按质量分数计，将1～30％的陶瓷纤维材料、10～70％的陶瓷颗粒材料、0.5～8％的低温粘合剂和0.5～10％的高温粘合剂，加入适量水均匀混合制成陶瓷浆料，再将该陶瓷浆料定量浇入预装有耐高温金属骨架的预制件模具中，加压20～30MPa，去水并压制成复合材料预制件半成品；然后将该复合材料预制件先在60～200℃温度下烘干处理10～20h，再在700～1000℃温度下烧结处理2.5～4h，得到复合材料预制件成品；最后采用挤压铸造工艺将该复合材料预制件成品复合于事先准备好的轻金属合金基体，使耐磨层预制件与轻金属合金基体冶金结合，即得到局部增强轻金属基复合材料。
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201711113030.3A CN107876730B (zh) | 2017-11-13 | 2017-11-13 | 耐磨材料、局部增强轻金属基复合材料及制备方法 |
| PCT/CN2017/000702 WO2019090445A1 (zh) | 2017-11-13 | 2017-11-27 | 耐磨材料、局部增强轻金属基复合材料及制备方法 |
| US16/071,078 US20210171403A1 (en) | 2017-11-13 | 2017-11-27 | Wear-resistant material, locally-reinforced light metal matrix composites and manufacturing method |
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| CN107917160B (zh) * | 2017-11-13 | 2019-08-20 | 宁波海瑞时新材料有限公司 | 一种制动盘及其制备方法 |
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| CN109128005B (zh) * | 2018-08-23 | 2019-12-24 | 东北大学 | 一种金属框架增韧陶瓷复合材料及其制备方法和应用 |
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| CN115921823B (zh) * | 2022-12-19 | 2023-08-15 | 有研工程技术研究院有限公司 | 一种高熵合金增强轻金属材料的制备加工方法 |
| CN116573947A (zh) * | 2023-04-27 | 2023-08-11 | 郑州航空工业管理学院 | 一种三维增韧陶瓷刀具材料及其制备方法 |
| CN117267285B (zh) * | 2023-11-21 | 2024-02-02 | 山西汤荣机械制造股份有限公司 | 一种便于散热的制动鼓及其铸造装置 |
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| WO2019090445A1 (zh) | 2019-05-16 |
| CN107876730A (zh) | 2018-04-06 |
| US20210171403A1 (en) | 2021-06-10 |
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