CN111138194A - 一种受电弓碳滑板复合材料的制备方法 - Google Patents

一种受电弓碳滑板复合材料的制备方法 Download PDF

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CN111138194A
CN111138194A CN202010035661.3A CN202010035661A CN111138194A CN 111138194 A CN111138194 A CN 111138194A CN 202010035661 A CN202010035661 A CN 202010035661A CN 111138194 A CN111138194 A CN 111138194A
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powder
slide plate
temperature
copper
carbon slide
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魏健
张锦俊
闵洁
张培林
庞中海
武建军
刘伟凯
纪永良
雷涛
霍有
张彦举
孟鹏
吕星薄
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Datong Xincheng New Material Co Ltd
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Abstract

本发明涉及碳滑板制备技术领域，更具体而言，涉及一种受电弓碳滑板复合材料的制备方法，通过在原料中加入铁红、钴粉、氧化铪、镍粉、铜粉、炭黑、石墨粉等，与原料中的其他材料相融合，可以补充成品碳滑板的机械强度，使其在运行中不易折断和破裂；其制备工艺是，首先对原料进行研磨，再通过模压成型、浸铜工艺、最后烧结炭化处理，可以增加碳滑板材料的密度和强度。制备的受电弓碳滑板复合材料体积密度8.0‑9.0g/cm3、抗拉强度≥180Mpa、冲击韧性≥12J/cm2、20℃电阻率≤0.20µΩ·m、洛氏硬度（HBS）60‑100。

Description

一种受电弓碳滑板复合材料的制备方法
技术领域
本发明涉及碳滑板制备技术领域，更具体而言，涉及一种受电弓碳滑板复合材料的制备方法。
背景技术
受电弓滑板是电力机车上的重要集电元件，安装在受电弓的最上部，直接与接触网导线接触，在列车走行过程中，从接触网导线上获得电流为机车供应电力。
受电弓碳滑板碳滑条材料必须具有良好的减磨性和自润滑性、良好的耐热和耐电弧性、一定的耐磨性、足够的抗冲击强度以及稳定的电阻率和接触电阻。
受电弓滑板通常采用石墨粉、焦碳粉、碳黑、粘结剂焦、石油焦等作为主要原料，中温煤粘结剂做粘结剂，铜、铝等材料做为浸渍剂等，使其自润滑性和减磨性能好，在与铜接触导线摩擦时可在导线上持续补给润滑炭膜，具有减少导线磨损及电导率的效果。但碳滑板在自然环境运行中遇到导线硬点容易造成滑板折断或破裂，特别是在雨季和潮湿地区，易局部拉沟，出现弓网事故。
随着电气化铁路朝着高密度、载重大、高速度的趋势发展，继续开发一种工艺简单、安全可靠的电力机车用受电弓滑板。
针对现有技术的缺陷，特提出本发明。
发明内容
为了克服现有技术中所存在的不足，本发明提供一种受电弓碳滑板复合材料的制备方法，以提高受电弓碳滑板的机械强度、电导性和耐冲击性能。
为了解决上述技术问题，本发明所采用的技术方案为：
一种受电弓碳滑板复合材料的制备方法，包括以下步骤：
S1、预热：将铁红、钴粉、钛粉、镍粉、铜粉分别在200-300℃的预热炉中预热，预热时间为30-60min；
S2、研磨：将上述所配得的铁红、钴粉、钛粉、镍粉、铜粉进行研磨，要求纯度为99.99%；研磨转速为350～600r/min，所述研磨的颗粒比为10-30:15-20:1-10；
S3、一次干混：将铁红、钴粉、钛粉、镍粉、铜粉按上述比例进行混捏，混捏温度为150℃～250℃，混捏时间为1～1.5h；混捏后粉料自然冷却至常温；
S4、二次干混：将一次干混后的原料与炭黑、石墨粉按上述比例进行混捏，混捏温度为160℃～220℃，混捏时间为1.5～3h，混捏后的粉料自然冷却至常温；
S5、湿混：二次料混粉后的混合料与粘结剂环氧树脂进行混捏，湿混粘结剂温度为120-170℃，湿混时间为40-60分钟；混捏机包括设置在混捏机上的自动报警装置，且自动报警装置用于设定时间到达时进行报警；混捏机内部的温度设置为160-220℃和120-170℃；
S6、模压成型：将湿混后的材料倒入模具中，利用双向压制模压成型制成一定形状和尺寸的压坯，并使之具有一定的密度和强度；利用冷却设备对碳滑板初胚进行冷却处理；
S7、一次焙烧为：将预成型的生坯装入焙烧炉中进行焙烧得到第一次坯体，焙烧温度为20℃～1250℃，并在1250℃温度下保温48h，焙烧时间为240h，出炉后自然冷却至常温；
S8、浸铜：将焙烧品称重后置入石墨坩埚中，将预热炉按升温曲线进行预热，再次，对铜进行融化，在预热炉中坩埚加热的过程当中，准备金属融化，通电前检查电路、水路是否畅通；将准备好的铜放入到融化池中，开始通电，将电流调至220A，通电2小时后铜化为液体符合浸金属要求；
坩埚从预热炉中拉出，放置在融化池下，将融化好的金属溶液倒入装有碳条的高温坩埚中，将高温坩埚放入真空设备中，确保无误后开始抽真空，当真空度达到0.085MPa后，真空结束，再次放入预热炉中预热半小时至室温后取出即可；增重率为33-35%，将熔融金属进行超声波处理，超声频率为100Hz，超声功率为0-100W，超声时间为10-30min；
S9、二次焙烧：将浸渍后的坯体放入焙烧炉中进行第二次焙烧得到第二次坯体，焙烧温度为20℃～1200℃，并在1200℃温度下保温48h，焙烧时间为300h，利用烘干设备对浸渍处理后的烧结墨烯碳滑板初胚进行烘干处理；
S10、所述后续处理是可根据制品性能的要求选择适当的后续处理工艺，如精整、机械加工、化学处理、电镀等，以满足产品的综合性能。
进一步地，所述受电弓碳滑板复合材料原料中，主要有：铁红、钴粉、钛粉、镍粉、铜粉、炭黑、石墨粉；粘结剂为环氧树脂；浸渍剂为液态铜。
进一步地，所述铁红的粒度D50为10-25nm；所述钴粉的粒度D50为15-30nm；所述钛粉的粒度D50为10-20nm；所述镍粉的粒度D50为10-35nm；所述铜粉的密度为8.92×103/cm3；所述炭黑的粒度D50为40-60nm；所述石墨粉的粒度D50为20-40nm。
进一步地，所述粘结剂环氧树脂的软化点为85～95℃。
进一步地，所述浸渍剂液态铜为99%纯铜。
进一步地，所述一次混粉为铁红、钴粉、钛粉、镍粉、铜粉的混合料，其重量比为8:12:20:25:35。
进一步地，所述二次混粉为混合料与炭黑、石墨粉的混合料，其重量比为25:40:35。
进一步地，所述湿混为混合料与粘结剂的混合物，其重量比为70:30-75:25。
与现有技术相比，本发明所具有的有益效果为：
本发明提供了一种受电弓碳滑板复合材料的制备方法，通过在原料中加入铁红、钴粉、氧化铪、镍粉、铜粉、炭黑、石墨粉等，与原料中的其他材料相融合，可以补充成品碳滑板的机械强度，使其在运行中不易折断和破裂；其制备工艺是，首先对原料进行研磨，再通过模压成型、浸铜工艺、最后烧结炭化处理，可以增加碳滑板材料的密度和强度。制备的受电弓碳滑板复合材料体积密度8.0-9.0g/cm3、抗拉强度≥180Mpa、冲击韧性≥12J/cm2、20℃电阻率≤0.20µΩ·m、洛氏硬度（HBS）60-100。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅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。
一种受电弓碳滑板复合材料的制备方法，包括以下步骤：
S1、预热：将铁红、钴粉、钛粉、镍粉、铜粉分别在200-300℃的预热炉中预热，预热时间为30-60min；
S2、研磨：将上述所配得的铁红、钴粉、钛粉、镍粉、铜粉进行研磨，要求纯度为99.99%；研磨转速为350～600r/min，所述研磨的颗粒比为10-30:15-20:1-10；
S3、一次干混：将铁红、钴粉、钛粉、镍粉、铜粉按上述比例进行混捏，混捏温度为150℃～250℃，混捏时间为1～1.5h；混捏后粉料自然冷却至常温；
S4、二次干混：将一次干混后的原料与炭黑、石墨粉按上述比例进行混捏，混捏温度为160℃～220℃，混捏时间为1.5～3h，混捏后的粉料自然冷却至常温；
S5、湿混：二次料混粉后的混合料与粘结剂环氧树脂进行混捏，湿混粘结剂温度为120-170℃，湿混时间为40-60分钟；混捏机包括设置在混捏机上的自动报警装置，且自动报警装置用于设定时间到达时进行报警；混捏机内部的温度设置为160-220℃和120-170℃；
S6、模压成型：将湿混后的材料倒入模具中，利用双向压制模压成型制成一定形状和尺寸的压坯，并使之具有一定的密度和强度；利用冷却设备对碳滑板初胚进行冷却处理；
S7、一次焙烧为：将预成型的生坯装入焙烧炉中进行焙烧得到第一次坯体，焙烧温度为20℃～1250℃，并在1250℃温度下保温48h，焙烧时间为240h，出炉后自然冷却至常温；
S8、浸铜：将焙烧品称重后置入石墨坩埚中，将预热炉按升温曲线进行预热，再次，对铜进行融化，在预热炉中坩埚加热的过程当中，准备金属融化，通电前检查电路、水路是否畅通；将准备好的铜放入到融化池中，开始通电，将电流调至220A，通电2小时后铜化为液体符合浸金属要求，将熔融金属进行超声波处理，超声频率为100Hz，超声功率为0-100W，超声时间为10-30min；
坩埚从预热炉中拉出，放置在融化池下，将融化好的金属溶液倒入装有碳条的高温坩埚中，将高温坩埚放入真空设备中，确保无误后开始抽真空，当真空度达到0.085MPa后，真空结束，再次放入预热炉中预热半小时至室温后取出即可；增重率为33-35%；
S9、二次焙烧：将浸渍后的坯体放入焙烧炉中进行第二次焙烧得到第二次坯体，焙烧温度为20℃～1200℃，并在1200℃温度下保温48h，焙烧时间为300h，利用烘干设备对浸渍处理后的烧结墨烯碳滑板初胚进行烘干处理；
S10、所述后续处理是可根据制品性能的要求选择适当的后续处理工艺，如精整、机械加工、化学处理、电镀等，以满足产品的综合性能。
在本实施例中，所述受电弓碳滑板复合材料原料中，主要有：铁红、钴粉、钛粉、镍粉、铜粉、炭黑、石墨粉；粘结剂为环氧树脂；浸渍剂为液态铜。
在本实施例中，所述铁红的粒度D50为10-25nm；所述钴粉的粒度D50为15-30nm；所述钛粉的粒度D50为10-20nm；所述镍粉的粒度D50为10-35nm；所述铜粉的密度为8.92×103/cm3；所述炭黑的粒度D50为40-60nm；所述石墨粉的粒度D50为20-40nm。
在本实施例中，所述粘结剂环氧树脂的软化点为85～95℃。
在本实施例中，所述浸渍剂液态铜为99%纯铜。
在本实施例中，所述一次混粉为铁红、钴粉、钛粉、镍粉、铜粉的混合料，其重量比为8:12:20:25:35。
在本实施例中，所述二次混粉为混合料与炭黑、石墨粉的混合料，其重量比为25:40:35。
在本实施例中，所述湿混为混合料与粘结剂的混合物，其重量比为70:30-75:25。
上面仅对本发明的较佳实施例作了详细说明，但是本发明并不限于上述实施例，在本领域普通技术人员所具备的知识范围内，还可以在不脱离本发明宗旨的前提下作出各种变化，各种变化均应包含在本发明的保护范围之内。

Claims (8)

1.一种受电弓碳滑板复合材料的制备方法，其特征在于，包括以下步骤：
S1、预热：将铁红、钴粉、钛粉、镍粉、铜粉分别在200-300℃的预热炉中预热，预热时间为30-60min；
S2、研磨：将铁红、钴粉、钛粉、镍粉、铜粉进行研磨，要求纯度为99.99%；研磨转速为350～600r/min，所述研磨的颗粒比为10-30:15-20:1-10；
S3、一次干混：将铁红、钴粉、钛粉、镍粉、铜粉混捏，混捏温度为150℃～250℃，混捏时间为1～1.5h；混捏后粉料自然冷却至常温；
S4、二次干混：将一次干混后的原料与炭黑、石墨粉按上述比例进行混捏，混捏温度为160℃～220℃，混捏时间为1.5～3h，混捏后的粉料自然冷却至常温；
S5、湿混：二次料混粉后的混合料与粘结剂环氧树脂进行混捏，湿混粘结剂温度为120-170℃，湿混时间为40-60分钟；混捏机包括设置在混捏机上的自动报警装置，且自动报警装置用于设定时间到达时进行报警；混捏机内部的温度设置为160-220℃和120-170℃；
S6、模压成型：将湿混后的材料倒入模具中，利用双向压制模压成型制成一定形状和尺寸的压坯，并使之具有一定的密度和强度；利用冷却设备对碳滑板初胚进行冷却处理；
S7、一次焙烧为：将预成型的生坯装入焙烧炉中进行焙烧得到第一次坯体，焙烧温度为20℃～1250℃，并在1250℃温度下保温48h，焙烧时间为240h，出炉后自然冷却至常温；
S8、浸铜：将焙烧品称重后置入石墨坩埚中，将预热炉按升温曲线进行预热，再次，对铜进行融化，在预热炉中坩埚加热的过程当中，准备金属融化，通电前检查电路、水路是否畅通；将准备好的铜放入到融化池中，开始通电，将电流调至220A，通电2小时后铜化为液体符合浸金属要求，将熔融金属进行超声波处理，超声频率为100Hz，超声功率为0-100W，超声时间为10-30min；
坩埚从预热炉中拉出，放置在融化池下，将融化好的金属溶液倒入装有碳条的高温坩埚中，将高温坩埚放入真空设备中，确保无误后开始抽真空，当真空度达到0.085MPa后，真空结束，再次放入预热炉中预热半小时至室温后取出即可；增重率为33-35%；
S9、二次焙烧：将浸渍后的坯体放入焙烧炉中进行第二次焙烧得到第二次坯体，焙烧温度为20℃～1200℃，并在1200℃温度下保温48h，焙烧时间为300h，利用烘干设备对浸渍处理后的烧结墨烯碳滑板初胚进行烘干处理；
S10、后续处理：根据制品性能的要求选择适当的后续处理工艺，如精整、机械加工、化学处理、电镀等，以满足产品的综合性能。
2.根据权利要求1所述的一种受电弓碳滑板复合材料的制备方法，其特征在于：所述受电弓碳滑板复合材料原料中，主要有：铁红、钴粉、钛粉、镍粉、铜粉、炭黑、石墨粉；粘结剂为环氧树脂；浸渍剂为液态铜。
3.根据权利要求1所述的一种受电弓碳滑板复合材料的制备方法，其特征在于：所述铁红的粒度D50为10-25nm；所述钴粉的粒度D50为15-30nm；所述钛粉的粒度D50为10-20nm；所述镍粉的粒度D50为10-35nm；所述铜粉的密度为8.92×103/cm3；所述炭黑的粒度D50为40-60nm；所述石墨粉的粒度D50为20-40nm。
4.根据权利要求1所述的一种受电弓碳滑板复合材料的制备方法，其特征在于：所述粘结剂环氧树脂的软化点为85～95℃。
5.根据权利要求1所述的一种受电弓碳滑板复合材料的制备方法，其特征在于：所述浸渍剂液态铜为99%纯铜。
6.根据权利要求1所述的一种受电弓碳滑板复合材料的制备方法，其特征在于：所述一次混粉为铁红、钴粉、钛粉、镍粉、铜粉的混合料，其重量比为8:12:20:25:35。
7.根据权利要求1所述的一种受电弓碳滑板复合材料的制备方法，其特征在于：所述二次混粉为混合料与炭黑、石墨粉的混合料，其重量比为25:40:35。
8.根据权利要求1所述的一种受电弓碳滑板复合材料的制备方法，其特征在于：所述湿混为混合料与粘结剂的混合物，其重量比为70:30-75:25。
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