CN108083831A - 一种陶瓷摩擦材料及其制备方法 - Google Patents

一种陶瓷摩擦材料及其制备方法 Download PDF

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CN108083831A
CN108083831A CN201711376454.9A CN201711376454A CN108083831A CN 108083831 A CN108083831 A CN 108083831A CN 201711376454 A CN201711376454 A CN 201711376454A CN 108083831 A CN108083831 A CN 108083831A
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ceramic
skeleton
binding agent
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solvent
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吴佩芳
释加才让
范叶明
党纵
党一纵
崔新亮
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Beijing Tianyishangjia New Material Co Ltd
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Abstract

本发明提供了一种陶瓷摩擦材料，涉及制动盘领域，本发明提供的陶瓷摩擦材料包括，纤维预制体骨架与包覆在所述纤维预制体骨架上的陶瓷材料，以及成核剂；所述陶瓷材料包括氧化铝、氧化锂、二氧化硅、三氧化钼、硅酸锆。本发明陶瓷摩擦材料采用成核剂，通过调节陶瓷材料中晶体种类和大小，有效提高了陶瓷材料的强度、硬度和断裂韧性，同时增加陶瓷材料与纤维之间的界面结合强度。

Description

一种陶瓷摩擦材料及其制备方法
技术领域
本发明涉及制动盘领域，具体涉及一种在高温下硬度高的陶瓷摩擦材料。
背景技术
制动盘又名刹车盘，是汽车制动系统的重要组成部件。制动盘在汽车运动时与车轮一起转动，刹车时制动卡钳夹住制动盘，与制动盘的摩擦面产生摩擦，进而起到减速的作用。所以制动盘的制动性能优良直接关系到行车的安全性。铁铸制动盘由于其价格低廉、原料来源广泛而被普遍应用。但是随着对汽车速度以及安全性能的要求不断提升，对制动盘的要求也不断提高。而铁铸制动盘由于其易热裂、耐磨性差已经渐渐不能满足高性能汽车的要求。将铝合金作为基体材料在其工作的表面上嵌入性能良好的摩擦材料作为工作面，这样在不降低制动盘制动性能的同时，极大的降低了制动盘的质量，但是铝合金材料热稳定性不佳，其在温度大于350℃后机械强度会急剧下降，出现盘体失稳等缺陷。这就要求嵌入在铝合金上的摩擦材料在具有良好的摩擦性能、高断裂韧性的同时，还要具有良好的隔热性。
中国专利CN105041921A一种基于编织纤维的摩擦材料及其制备方法，其公开了基于编织纤维的摩擦材料包括有机弹性体、编织纤维、增强填料、摩擦调节剂和偶联剂。其中增强填料包括氧化铜、氧化铝、碳化硅、氮化硅、碳纳米管、氧化铬、氧化钛、氧化硅、铜金粉、钛酸钾、氧化锌和氮化硼中的一种或几种。有机弹性体为橡胶类。该摩擦材料以编织纤维作为骨架，不仅增强了摩擦材料的断裂韧性，而且也提高了摩擦材料的隔热性能；并且其加入了橡胶类材料作为有机弹性体调节摩擦材料的硬度，避免材料硬度过高对对偶的损伤过大。但是该种材料的热稳定性同样不佳，在在300-400℃时，该摩擦材料中的橡胶成分会发生软化，出现结构失稳的情况，导致该摩擦材料的硬度以及摩擦性能下降。
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的摩擦材料的热稳定差，导致其硬度以及摩擦性能下降的缺陷。从而提供一种陶瓷么擦材料。
为此，本发明提供如下技术方案：
一种陶瓷摩擦材料，包括，纤维预制体骨架与包覆在其上的陶瓷材料，以及成核剂；所述陶瓷材料包括氧化锂、二氧化硅、氧化铝、三氧化钼和硅酸锆。
所述陶瓷材料与所述碳纤维预制体骨架的质量比为50-75：25-50。
所述纤维预制体骨架选自碳纤维、玄武岩纤维、碳化硅纤维中的一种。
所述纤维预制体骨架结构为针刺编织的2.5维预制体或三维编织预制体。
所述的成核剂选自二氧化钛、二氧化锆、五氧化二磷与三氧化二硼中一种或几种。
所述陶瓷材料制备时需要相应的粘结剂。
所述粘结剂由溶质和溶剂两部分组成，其中溶质选自硅溶胶、正硅酸乙酯、硅烷偶联剂、铝溶胶、钛酸四丁酯和磷酸二氢铝中一种或几种，其中溶剂选自去离子水和/或无水乙醇。
所述氧化锂、所述二氧化硅、所述氧化铝、所述三氧化钼、所述硅酸锆的质量比为：1-5：55-70：2-30：0-10：0-5。
所述陶瓷材料、所述碳纤维预制体骨架、所述成核剂、所述粘结剂的质量比为50-75：25-50：0.5-10：0.5-10：17-35。
一种制备所述陶瓷摩擦材料的方法，包括如下步骤：
(1)将氧化锂、二氧化硅、氧化铝、三氧化钼、硅酸锆、成核剂与粘结剂混合，得到陶瓷浆液；
(2)将纤维布堆垛成型，层与层之间碳纤维取向呈0～90°的角度，层之间采用针刺法或三维编织法进行固定处理，而后在200℃～600℃进行中温排胶处理，得到纤维预制体骨架；
(3)将纤维预制体骨架浸泡在陶瓷浆液中，浸渍的时间0.5h～3.0h，温度30℃～90℃之间，所述陶瓷浆液的浓度10％～40wt.％；
(4)纤维预制体骨架浸浆后先加热至85℃～200℃在干燥环境中排除多余的溶剂；
(5)重复步骤(3)和步骤(4)，直至达到纤维预制体骨架与陶瓷浆液的质量比为1:2～20，在1400℃～1800℃，20MPa～200MPa下，热压处理，从而得到所述陶瓷摩擦材料。
所述粘结剂由溶质和溶剂两部分组成，其中溶质选自硅溶胶、正硅酸乙酯、硅烷偶联剂、铝溶胶、钛酸四丁酯和磷酸二氢铝中一种或几种，其中溶剂选自去离子水和/或无水乙醇。所述粘结剂加入到步骤(1)的陶瓷浆液中。
所述陶瓷浆液中，所述氧化锂、所述二氧化硅、所述氧化铝、所述三氧化钼、所述硅酸锆、成核剂、粘结剂和溶剂的质量比为：2-30：1-5：55-70：1-10：1-5:0.5-10:0.5-10：2.5-50。
本发明技术方案，具有如下优点：
1.本发明提供了一种陶瓷摩擦材料，包括，纤维预制体骨架和包覆在所述纤维预制体骨架上的陶瓷材料，以及成核剂；
所述陶瓷材料包括氧化铝、氧化锂、二氧化硅、三氧化钼和硅酸锆。所述复合纤维中，采用成核剂，不仅可以调节陶瓷材料的晶体的种类和大小，从而有效的提高了陶瓷材料了硬度和断裂韧性，而且能有效的增加陶瓷材料与纤维的粘合性。
2.本发明提供了一种陶瓷摩擦材料，通过氧化铝、氧化镁、二氧化硅和硅酸锆组成的所述陶瓷材料与所述纤维预制体骨架的质量比为50-75：25-50；
氧化铝、氧化锂、二氧化硅、三氧化钼和硅酸锆、粘结剂和成核剂复配使用，提高了陶瓷摩擦材料的热稳定性，其中三氧化钼和硅酸锆的加入起到了摩擦系数调节剂的作用；经过检测，在20℃布氏硬度可达到62，在400℃布氏硬度可以达到59，在1000℃下的热失重＜5wt％。
具体实施方式
下面将对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。此外，下面所描述的本发明不同实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互结合。
实施例1-7
本实施例提供了一种陶瓷摩擦材料制备方法，包括如下步骤：
(1)将氧化锂、二氧化硅、氧化铝、三氧化钼、硅酸锆、成核剂与粘结剂混合，得到陶瓷浆液；
(2)将纤维预制体骨架浸泡在陶瓷浆液中，浸渍的时间0.5h～2.0h，温度50℃～90℃，纤维预制体骨架与陶瓷浆液的质量用量比1:2-20，陶瓷浆液的浓度20％～40％；
(3)纤维预制体骨架浸浆后先加热至85℃～200℃在干燥环境中排除多余的溶剂，将所述纤维预制体骨架编织成碳纤维布；
(4)将纤维布堆垛成型，层与层之间纤维取向呈0～90°的角度，层之间采用针刺法进行固定处理，而后在200℃～600℃排胶处理，目的是降低后续热压烧结时残留溶剂的气化作用导致的复合材料不致密的问题，得到摩擦材料预制体；
(5)在1400℃～1800℃，20Mpa～500MPa下，热压处理，从而得到所述陶瓷摩擦材料。
表1实施例1-7各组分重量份配比
实施例 1 2 3 4 5 6 7
纤维预制体骨架 35 25 40 50 30 45 28
陶瓷材料 50 75 55 65 60 70 67
成核剂 3 5 8 0.5 10 9 6
粘结剂 0.5 10 5 8 10 3.5 4.5
表2实施例1-7的陶瓷材料的配比
实施例(wt.％) 1 2 3 4 5 6 7
氧化锂 1 5 2 3 4 1.5 2.3
二氧化硅 69 67 63 58 70 65 55
氧化铝 2 15 8 20 10 30 25
三氧化钼 8 10 0 7 9 3 5
硅酸锆 1 2 3 0 4 3 1.5
表3实施例1-7的成核剂成分以及重量份配比
表4实施例1-7的粘结剂原料以及溶剂的成分的重量份配比粘结剂和溶剂0.5-10：2.5-50
表5实施例1-7的纤维预制体骨架的的选择
实施例1 碳纤维
2 玄武岩纤维
3 碳化硅纤维
4 碳纤维
5 玄武岩纤维
6 碳化硅纤维
7 玄武岩纤维
效果验证
1.在高温和常温下对陶瓷摩擦复合材料的硬度测试；
用THB-3000MDX触摸屏布氏硬度计，选用压痕法对实施例1-7制备的陶瓷摩擦材料在温度为20℃和400℃下的布氏硬度(HBW)进行检测；测试结果见表6。
具体为：将实施例1-7制备的陶瓷摩擦材料切割成尺寸为20mm×20mm×10mm的试验块，压头直径10mm。
表6
实施例 1 2 3 4 5 6 7
布氏硬度(20℃) 59 58 62 60 57 59 61
布氏硬度(400℃) 58 55 55 59 58 58 57
2.对陶瓷摩擦复合材料在高温和常温下的摩擦系数0.35-0.50之间取值范围的检测
按照《SAE J2522》测功圆盘制动器效能标准对实施例1-7制备的陶瓷摩擦材料的摩擦系数进行检测，检测结果见表7。
表7
实施例 1 2 3 4 5 6 7
摩擦系数 0.443 0.445 0.442 0.439 0.451 0.447 0.450
3.对陶瓷摩擦复合材料的导热系数进行检测
采用德国耐驰LFA447激光导热系数测量仪对实施例1-7制备的陶瓷摩擦材料的摩擦系数进行检测，检测结果见表8。
具体测试为：实施例1-7制备的陶瓷摩擦材料切割成尺寸为Φ12.6mm×3.0mm的测试样，测试标按照国际标准ASTM E 1461，测试温度为20℃。
表8
4.对陶瓷摩擦材料的断裂韧性、膨胀系数、杨氏弹性模量、抗弯强度进行检测
对实施例1-7制备的陶瓷摩擦材料的断裂韧性、膨胀系数、杨氏弹性模量、抗弯强度检测，检测结果见9。
表9
5.对陶瓷摩擦复合材料热失重进行检测
对实施例1-7制备的陶瓷摩擦材料热失重进行检测，具体测试方法为：
将陶瓷摩擦材料切割成尺寸为Φ30mm×10mm的样品，在室温20℃，对样品在分析天平上对质量进行称量。之后将样品放入中温炉中，空气环境下加热至1000℃，保温1h后，取出待冷却至室温后，干态样品再次在分析天平上进行称量，测试结果见表10。
表10
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)

1.一种陶瓷摩擦材料，其特征在于，包括，纤维预制体骨架与包覆在其上的陶瓷材料，以及成核剂；所述陶瓷材料包括氧化锂、二氧化硅、氧化铝、三氧化钼和硅酸锆。
2.根据权利要求1所述的陶瓷摩擦材料，其特征在于，所述陶瓷材料与所述碳纤维预制体骨架的质量比为50-75：25-50。
3.根据权利要求2所述的陶瓷摩擦材料，其特征在于，所述纤维预制体骨架选自碳纤维、玄武岩纤维、碳化硅纤维中的一种。
4.根据权利要求3所述的陶瓷摩擦材料，其特征在于，所述纤维预制体骨架结构为针刺编织的2.5维预制体或三维编织预制体。
5.根据权利要求4所述的陶瓷摩擦材料，其特征在于，所述的成核剂选自二氧化钛、二氧化锆、五氧化二磷与三氧化二硼中一种或几种。
6.根据权利要求5所述的陶瓷摩擦材料，其特征在于，所述陶瓷材料制备时需要相应的粘结剂。
7.根据权利要求6所述的粘结剂，其特征在于，所述粘结剂由溶质和溶剂两部分组成，其中溶质选自硅溶胶、正硅酸乙酯、硅烷偶联剂、铝溶胶、钛酸四丁酯和磷酸二氢铝中一种或几种，其中溶剂选自去离子水和/或无水乙醇。
8.根据权利要求7所述的陶瓷摩擦材料，其特征在于，所述氧化锂、所述二氧化硅、所述氧化铝、所述三氧化钼、所述硅酸锆的质量比为：1-5：55-70：2-30：0-10：0-5。
9.根据权利要求8所述的陶瓷摩擦材料，其特征在于，所述陶瓷材料、所述碳纤维预制体骨架、所述成核剂、所述粘结剂的质量比为50-75：25-50：0.5-10：0.5-10。
10.一种制备权利要求1-9任一所述陶瓷摩擦材料的方法，包括如下步骤：
(1)将氧化锂、二氧化硅、氧化铝、三氧化钼、硅酸锆、成核剂与粘结剂混合，得到陶瓷浆液；
(2)将纤维布堆垛成型，层与层之间碳纤维取向呈0～90°的角度，层之间采用针刺法或三维编织法进行固定处理，而后在200℃～600℃进行中温排胶处理，得到纤维预制体骨架；
(3)将纤维预制体骨架浸泡在陶瓷浆液中，浸渍的时间0.5h～3.0h，温度30℃～90℃之间，所述陶瓷浆液的浓度10％～40wt.％；
(4)纤维预制体骨架浸浆后先加热至85℃～200℃在干燥环境中排除多余的溶剂；
(5)重复步骤(3)和步骤(4)，直至达到纤维预制体骨架与陶瓷浆液的质量比为1:2～20，在1400℃～1800℃，20MPa～200MPa下，热压处理，从而得到所述陶瓷摩擦材料。
11.根据权利要求10所述的制备方法，其特征在于，所述粘结剂由溶质和溶剂两部分组成，其中溶质选自硅溶胶、正硅酸乙酯、硅烷偶联剂、铝溶胶、钛酸四丁酯和磷酸二氢铝中一种或几种，其中溶剂选自去离子水和/或无水乙醇；
所述陶瓷浆液中，所述氧化锂、所述二氧化硅、所述氧化铝、所述三氧化钼、所述硅酸锆、成核剂、粘结剂和溶剂的质量比为：2-30：1-5：55-70：1-10：1-5:0.5-10:0.5-10：2.5-50。
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