CN110106405B - 一种制动盘用SiCp-Al复合材料的制备方法 - Google Patents

一种制动盘用SiCp-Al复合材料的制备方法 Download PDF

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CN110106405B
CN110106405B CN201910405922.3A CN201910405922A CN110106405B CN 110106405 B CN110106405 B CN 110106405B CN 201910405922 A CN201910405922 A CN 201910405922A CN 110106405 B CN110106405 B CN 110106405B
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王炳福
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Abstract

本发明涉及SiCp‑Al复合材料制备技术领域,且公开了一种制动盘用SiCp‑Al复合材料的制备方法,先将粒径大小基本相同的Al粉与SiCp,在三聚磷酸钠分散剂和气相二氧化硅防沉剂的共同作用下,均匀分散在易挥发的无水乙醇溶剂中,接着在环氧树脂的粘合作用下,Al粉与SiCp复合形成分布均一的浆料,最后将浆料压制成型烧结,制备得到制动盘用SiCp‑Al复合材料。本发明解决了目前用于制备SiCp‑Al复合材料的离心浇铸法,在制备SiCp‑Al复合材料的过程中,存在的增强体SiC陶瓷颗粒在基体金属Al中分布不均匀与发生团聚的技术问题。

Description

一种制动盘用SiCp-Al复合材料的制备方法
技术领域
本发明涉及SiCp-Al复合材料制备技术领域,具体为一种制动盘用SiCp-Al复合材料的制备方法。
背景技术
交通运输车辆轻量化、高速化、低能耗已成为车辆发展的必然趋势。为了满足高速列车制动要求,一方面,对现有的制动装置进行改进;另一方面,对现有制动材料进行改进,传统的车辆制动盘采用铸铁或者铸钢制造,由于导热性能差,在大制动功率下热容量不足,易产生热龟裂而报废,所以只有通过发展新型制动材料才能满足高速列车对制动材料的要求。
而碳化硅陶瓷颗粒增强铝基复合材料(SiCp-Al)具有密度低、比强度高、比刚度高、耐磨性能优异,以及良好的导热性能和低的热膨胀系数等优点,在制动材料方面有着广阔的应用前景。目前SiCp-Al复合材料的制备方法有很多,但是其中最经济和最具有吸引力的是重力或离心浇铸法,具体为:将SiC粉末混合在熔化的液态铝中,在凝固过程中SiC颗粒(SiCp)在离心力作用下不断运动,最后形成SiCp浓度有一定梯度分布的铸件。
但是,上述SiCp-Al复合材料的制备方法存在以下问题:在离心铸造SiC粒子增强金属Al基复合材料的过程中,增强体SiC颗粒会发生偏析,在横截面上,越靠近铸件外测周边,SiC粒子的体积百分数越高;随着向内侧推移,增强体SiC颗粒的含量有所降低,在距铸件外侧周边一定距离处,SiC粒子含量急剧下降,很快便进入宽度最大而无增强体SiC颗粒的区域;在靠近铸件内侧周边处,在基体金属Al中分布着少量团聚的增强体SiC颗粒。然而保证增强体SiC颗粒在基体金属Al中分布均匀,且不出现团聚,是制备SiCp-Al复合材料需要解决的关键问题。
本发明提供一种制动盘用SiCp-Al复合材料的制备方法,旨在解决目前用于制备SiCp-Al复合材料的离心浇铸法,在制备SiCp-Al复合材料的过程中,存在的增强体SiC陶瓷颗粒在基体金属Al中分布不均匀与发生团聚的技术问题。
发明内容
(一)解决的技术问题
针对现有技术的不足,本发明提供了一种制动盘用SiCp-Al复合材料的制备方法,解决了目前用于制备SiCp-Al复合材料的离心浇铸法,在制备SiCp-Al复合材料的过程中,存在的增强体SiC陶瓷颗粒在基体金属Al中分布不均匀与发生团聚的技术问题。
(二)技术方案
为实现上述目的,本发明提供如下技术方案:
一种制动盘用SiCp-Al复合材料的制备方法,包括以下步骤:
(1)称取80~100份Al粉与无水乙醇一起置于球磨罐中,在N2保护下进行球磨2~4h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的Al粉;
(2)将80~100份SiCp与无水乙醇一起置于球磨罐中,在N2保护下进行球磨2~4h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的SiCp;
(3)将500份无水乙醇加入到装有搅拌装置和加热装置的反应器中,在转速为300~500rpm的搅拌下,先加入3~5份分散剂和2~6份防沉剂,再缓慢步骤(1)制备的Al粉,最后加入步骤(2)制备的SiCp,转为900~1200rpm搅拌2~4h;
在转速为300~500rpm的搅拌下,加入15~30份环氧树脂,转为900~1200rpm搅拌1~3h,加热蒸发除去无水乙醇;
(4)先将复合浆料装入等静压橡胶模具中,在250~300MPa压力下压制成型,再放置在烧结炉中,于850℃、15MPa下保温2~3h,制备得到SiCp-Al复合材料。
优选的,所述步骤(3)中,分散剂为三聚磷酸钠、防沉剂为气相二氧化硅。
优选的,所述步骤(3)中,环氧树脂为双酚A型E51,其环氧值0.48~0.54eg/mg。
优选的,所述步骤(4)中,复合浆料压制成型后,放置在氮气保护气氛的烧结炉中进行烧结。
(三)有益的技术效果
与现有技术相比,本发明具备以下有益的技术效果:
先将粒径大小基本相同的Al粉与SiCp,在三聚磷酸钠分散剂和气相二氧化硅防沉剂的共同作用下,均匀分散在易挥发的无水乙醇溶剂中,接着在环氧树脂的粘合作用下,Al粉与SiCp复合形成分布均一的浆料,最后将浆料压制成型烧结,制备得到制动盘用SiCp-Al复合材料,从而取得了在制备SiCp-Al复合材料的过程中,增强体SiC陶瓷颗粒在基体金属Al中实现均一分布的技术效果;
且本发明制备出的SiCp-Al复合材料的抗拉强度为158~165MPa、硬度为79~86、密度为2.21~2.26g/cm3,与对比例中的SiCp-Al复合材料的抗拉强度115MPa、硬度为58、密度为2.24g/cm3相比,取得了显著提高SiCp-Al复合材料的抗拉强度与硬度的技术效果。
具体实施方式
实施例一:
(1)称取80g Al粉与50g无水乙醇一起置于球磨罐中,在N2保护下进行球磨2h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的Al粉;
(2)将80gSiCp与100g无水乙醇一起置于球磨罐中,在N2保护下进行球磨2h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的SiCp;
(3)将500g无水乙醇加入到装有搅拌装置和加热装置的反应器中,在转速为300rpm的搅拌下,先加入3g三聚磷酸钠分散剂和2g气相二氧化硅防沉剂,再缓慢步骤(1)制备的Al粉,最后加入步骤(2)制备的SiCp,转为900rpm搅拌2h;
在转速为300rpm的搅拌下,加入15g双酚A型E51环氧树脂,转为900rpm搅拌1h,同时将反应器加热到100℃,并在100℃做保温处理,直至无水乙醇完全蒸发除去;
(4)先将复合浆料装入等静压橡胶模具中,在250MPa压力下压制成型,再放置在氮气保护气氛烧结炉中,以10℃/min的升温速率,升温至800℃,并于850℃、15MPa下保温2h,退火,冷却至室温后取出,制备得到SiCp-Al复合材料;
(5)在Instron8032万能电子拉伸仪上,测量上述SiCp-Al复合材料的抗拉强度为165MPa,并在HBRVU-187.5型布洛维光学硬度计测量仪上测量上述SiCp-Al复合材料的硬度为79,采用排水法测量上述SiCp-Al复合材料的密度为2.21g/cm3
实施例二:
(1)称取100g Al粉与50g无水乙醇一起置于球磨罐中,在N2保护下进行球磨4h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的Al粉;
(2)将100gSiCp与100g无水乙醇一起置于球磨罐中,在N2保护下进行球磨4h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的SiCp;
(3)将500g无水乙醇加入到装有搅拌装置和加热装置的反应器中,在转速为500rpm的搅拌下,先加入5g三聚磷酸钠分散剂和6g气相二氧化硅防沉剂,再缓慢步骤(1)制备的Al粉,最后加入步骤(2)制备的SiCp,转为1200rpm搅拌4h;
在转速为500rpm的搅拌下,加入30g双酚A型E51环氧树脂,转为1200rpm搅拌3h,同时将反应器加热到100℃,并在100℃做保温处理,直至无水乙醇完全蒸发除去;
(4)先将复合浆料装入等静压橡胶模具中,在300MPa压力下压制成型,再放置在氮气保护气氛烧结炉中,以10℃/min的升温速率,升温至850℃,并于850℃、15MPa下保温3h,退火,冷却至室温后取出,制备得到SiCp-Al复合材料;
(5)在Instron8032万能电子拉伸仪上,测量上述SiCp-Al复合材料的抗拉强度为158MPa,并在HBRVU-187.5型布洛维光学硬度计测量仪上测量上述SiCp-Al复合材料的硬度为86,采用排水法测量上述SiCp-Al复合材料的密度为2.26g/cm3
实施例三:
(1)称取90g Al粉与50g无水乙醇一起置于球磨罐中,在N2保护下进行球磨3h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的Al粉;
(2)将90gSiCp与100g无水乙醇一起置于球磨罐中,在N2保护下进行球磨3h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的SiCp;
(3)将500g无水乙醇加入到装有搅拌装置和加热装置的反应器中,在转速为400rpm的搅拌下,先加入4g三聚磷酸钠分散剂和4g气相二氧化硅防沉剂,再缓慢步骤(1)制备的Al粉,最后加入步骤(2)制备的SiCp,转为1000rpm搅拌3h;
在转速为400rpm的搅拌下,加入25g双酚A型E51环氧树脂,转为1000rpm搅拌2h,同时将反应器加热到100℃,并在100℃做保温处理,直至无水乙醇完全蒸发除去;
(4)先将复合浆料装入等静压橡胶模具中,在280MPa压力下压制成型,再放置在氮气保护气氛烧结炉中,以10℃/min的升温速率,升温至830℃,并于850℃、15MPa下保温2.5h,退火,冷却至室温后取出,制备得到SiCp-Al复合材料;
(5)在Instron8032万能电子拉伸仪上,测量上述SiCp-Al复合材料的抗拉强度为161MPa,并在HBRVU-187.5型布洛维光学硬度计测量仪上测量上述SiCp-Al复合材料的硬度为83,采用排水法测量上述SiCp-Al复合材料的密度为2.23g/cm3
对比例:
(1)称取90g Al粉与50g无水乙醇一起置于球磨罐中,在N2保护下进行球磨3h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的Al粉;
(2)将90gSiCp与100g无水乙醇一起置于球磨罐中,在N2保护下进行球磨3h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10um的SiCp;
(3)将500g无水乙醇加入到装有搅拌装置和加热装置的反应器中,在转速为400rpm的搅拌下,缓慢步骤(1)制备的Al粉,最后加入步骤(2)制备的SiCp,转为1000rpm搅拌3h;
(4)先将复合浆料装入等静压橡胶模具中,在280MPa压力下压制成型,再放置在氮气保护气氛烧结炉中,以10℃/min的升温速率,升温至830℃,并于850℃、15MPa下保温2.5h,退火,冷却至室温后取出,制备得到SiCp-Al复合材料;
(5)在Instron8032万能电子拉伸仪上,测量上述SiCp-Al复合材料的抗拉强度为115MPa,并在HBRVU-187.5型布洛维光学硬度计测量仪上测量上述SiCp-Al复合材料的硬度为58,采用排水法测量上述SiCp-Al复合材料的密度为2.24g/cm3
其中,双酚A型E51环氧树脂(环氧值0.48~0.54eg/mg,40℃时的粘度<2500Pa·s,南通星辰合成材料有限公司)。

Claims (2)

1.一种制动盘用SiCp-Al复合材料的制备方法,其特征在于,包括以下步骤:
(1)称取80~100重量份Al粉与无水乙醇一起置于球磨罐中,在N2保护下进行球磨2~4h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10μm的Al粉;
(2)将80~100重量份SiCp与无水乙醇一起置于球磨罐中,在N2保护下进行球磨2~4h,之后,干燥蒸发除去无水乙醇,过1340目筛,得到平均粒径≤10μm的SiCp
(3)将500重量份无水乙醇加入到装有搅拌装置和加热装置的反应器中,在转速为300~500rpm的搅拌下,先加入3~5重量份分散剂和2~6重量份防沉剂,再缓慢加入 步骤(1)制备的Al粉,最后加入步骤(2)制备的SiCp,转为900~1200rpm搅拌2~4h;
在转速为300~500rpm的搅拌下,加入15~30重量份环氧树脂,转为900~1200rpm搅拌1~3h,加热蒸发除去无水乙醇;
(4)先将复合浆料装入等静压橡胶模具中,在250~300MPa压力下压制成型,再放置在烧结炉中,于850℃、15MPa下保温2~3h,制备得到SiCp-Al复合材料;
其中,所述步骤(3)中,分散剂为三聚磷酸钠,防沉剂为气相二氧化硅;
其中,所述步骤(4)中,复合浆料压制成型后,放置在氮气保护气氛的烧结炉中进行烧结。
2.根据权利要求1所述的制备方法,其特征在于,所述步骤(3) 中,环氧树脂为双酚A型E51,其环氧值0.48~0.54eg/mg。
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