CN111231434A - 高性能复合摩擦材料及其制备方法 - Google Patents
高性能复合摩擦材料及其制备方法 Download PDFInfo
- Publication number
- CN111231434A CN111231434A CN202010119318.7A CN202010119318A CN111231434A CN 111231434 A CN111231434 A CN 111231434A CN 202010119318 A CN202010119318 A CN 202010119318A CN 111231434 A CN111231434 A CN 111231434A
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- CN
- China
- Prior art keywords
- fiber
- friction
- percent
- paper
- pulp
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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- 239000010410 layer Substances 0.000 claims abstract description 37
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 32
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- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 claims abstract description 15
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 claims description 10
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- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 claims description 2
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- FWDBOZPQNFPOLF-UHFFFAOYSA-N ethenyl(triethoxy)silane Chemical compound CCO[Si](OCC)(OCC)C=C FWDBOZPQNFPOLF-UHFFFAOYSA-N 0.000 claims description 2
- 239000010439 graphite Substances 0.000 claims description 2
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- 241000018650 Pinus massoniana Species 0.000 description 14
- 239000000919 ceramic Substances 0.000 description 10
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- 244000226021 Anacardium occidentale Species 0.000 description 6
- 230000005540 biological transmission Effects 0.000 description 6
- 235000020226 cashew nut Nutrition 0.000 description 6
- 241000196324 Embryophyta Species 0.000 description 4
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 238000005562 fading Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
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- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
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- 230000009347 mechanical transmission Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000004482 other powder Substances 0.000 description 1
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- 238000005245 sintering Methods 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
Classifications
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- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
- D21H13/46—Non-siliceous fibres, e.g. from metal oxides
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- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
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Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Inorganic Chemistry (AREA)
- Ceramic Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Engineering & Computer Science (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Dispersion Chemistry (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Braking Arrangements (AREA)
Abstract
本发明涉及一种高性能复合摩擦材料及其制备方法,所属复合材料技术领域,包括纸基复合材料中间层,纸基复合材料中间层上端设有陶瓷材料面层,纸基复合材料中间层下端设有环形摩擦盘片底层。陶瓷材料面层包含以下质量百分比的原料:氧化铝纤维40%~60%;钢纤维15%~30%;硅酸铝纤维15%~30%;填料和摩擦性能调节剂10%~30%。纸基复合材料中间层包含以下质量百分比的组分:柔性植物纤维40%~60%;芳纶浆粕5%~10%;碳纤维10%~20%;摩擦粉2%~8%;填料及添加剂15%~30%;改性酚醛树脂20%~40%。具有操作方便、成本相对低廉、摩擦系数稳定、磨损率低和耐热系数高的优点。解决了使用寿命短的问题。实现了两种摩擦材料在性能方面的优势互补。
Description
技术领域
本发明涉及复合材料技术领域,具体涉及一种高性能复合摩擦材料及其制备方法。
背景技术
摩擦装置是机械传动中的重要部件,广泛应用于船舶动力传动、车辆传动系统、农业与工程机械的传动系统以及军民用飞机刹车制动系统、工程及矿用湿式桥制动系统等领域。摩擦装置的性能主要取决于摩擦片的摩擦磨损性能。目前,现有国产摩擦片在使用过程中存在摩擦性能不稳定、磨损率高、耐热性能差等问题,与日本、美国、德国等发达国家存在一定差距。研制摩擦性能稳定、耐热性能好、耐磨损的摩擦片,提高设备总成机动性能,成为当下亟待解决的问题。
摩擦材料作为摩擦装置的关键材料,是以增强纤维、粘结剂(树脂与橡胶)、摩擦性能调节剂为主要组分经一系列制造加工工艺制成的多元复合材料。按照材质,摩擦材料可分为石棉基摩擦材料,半金属摩擦材料,粉末冶金摩擦材料、碳纤维摩擦材料、陶瓷基摩擦材料以及混合纤维型摩擦材料。石棉基摩擦材料因对人体有害,目前已被禁止使用;半金属摩擦材料以钢和铜等金属纤维作为增强纤维,同时含有粘结剂、摩擦性能调节剂、填料等成分。半金属摩擦材料具有较好的热稳定性、耐磨性和导热性,在400oC以下具有非常稳定的摩擦系数,在轿车、中重型汽车的盘式制动器中得到广泛应用,但成本相对较高;粉末冶金摩擦材料是以铁、铜、铝、镍、陶瓷等粉末作为基体,添加适当摩擦性能调节剂以及低熔点成分,经混合、压型,高温下烧结而成,在高负荷条件下表现出良好的摩擦性,在导热性和耐热性方面具有独特优势,被广泛应用于飞机、高速列车、重载汽车、重型工程机械的制动与传动,但价格高,制备技术繁杂、制动噪音大、对偶磨损大;碳纤维摩擦材料是各类摩擦材料中性能最好的一种,具有模量高、导热性能好、耐热性能强等特点,适合生产飞机及高档轿车的制动片;陶瓷基摩擦材料是指加入一定比例的陶瓷组分或具有陶瓷性能的氧化物且整体表现出部分陶瓷性能的摩擦材料,一般由陶瓷纤维、填料、粘结剂和少量金属组成,陶瓷摩擦材料具有较高的摩擦系数和抗压强度,较低的热膨胀系数,抗滑动磨损和抗蚀性好,可承受高的表面温度,近年来在摩擦材料研究领域逐渐受到关注。混合纤维型摩擦材料采用多种天然纤维、合成纤维、有机纤维等混合作为增强材料,充分利用每一种纤维的优势,通过热压固化成形,成本低,主要适用于轿车和轻、中型汽车制动片。
纸基复合材料中间层属于混合纤维型摩擦材料的一种,具有疏松多孔的结构,且回弹性能好,因采用类似造纸的生产工艺,因而被称为“纸基”摩擦材料。纸基摩擦材料主要由纤维、粘结剂、摩擦性能调节剂、填料、乳胶、促进剂等组成,具有摩擦系数高、动静摩擦系数比可调、耐磨损性能良好、能量吸收能力高,传送扭矩能力强、结合柔和、噪音小、不伤对偶等一系列优点,是目前世界上产量最大、应用最为广泛的湿式摩擦材料之一,被广泛用于各类车辆和工程机械、机床、船舶、矿山机械等行业湿式离合器和制动器中,特别是作为汽车自动变速器中湿式离合器的摩擦材料。但目前国内纸基摩擦材料的强度稳定性较差,热衰退率和磨损率高,产品粘结性能差,各组分分布均匀性也存在问题,这也是制约其大规模推广应用的关键。
发明内容
本发明主要解决现有技术中存在强度稳定性较差、热衰退率及磨损率高、产品粘结性能差和各组分分布均匀性不佳的不足,提供了一种高性能复合摩擦材料及其制备方法,其具有操作方便、成本相对低廉、摩擦系数稳定、磨损率低和耐热系数高的优点。解决了使用寿命短的问题。实现了两种摩擦材料在性能方面的优势互补。
本发明的上述技术问题主要是通过下述技术方案得以解决的:
一种高性能复合摩擦材料,包括纸基复合材料中间层,所述的纸基复合材料中间层上端设有陶瓷材料面层,所述的纸基复合材料中间层下端设有环形摩擦盘片底层;所述的陶瓷材料面层包含以下质量百分比的原料:氧化铝纤维40%~60%;钢纤维15%~30%;硅酸铝纤维15%~30%;填料和摩擦性能调节剂10%~30%。
作为优选,所述的纸基复合材料中间层包含以下质量百分比的组分:柔性植物纤维40%~60%;芳纶浆粕5%~10%;碳纤维10%~20%;摩擦粉2%~8%;填料及添加剂 15%~30%;改性酚醛树脂20%~40%。
作为优选,所述的碳纤维的宽度为1~3 mm,长度为8~15 mm;所述的柔性植物纤维包括针叶木浆、阔叶木浆、棉浆中的一种或几种;其中针叶木浆和阔叶木浆打浆度为25~35°SR,纤维长度1.5~5mm,宽25~40μm;棉浆打浆度为20~30°SR,纤维长度1~5mm,宽20~35μm;所述的芳纶浆粕长度0.5~2 mm,宽 25~20μm。打浆度也叫叩解度,用°SR表示。表示在铜网上抄造纸张时,浆料滤水快慢的程度,是衡量纸浆质量的指标之一。
作为优选,所述的氧化铝纤维平均长度 2~5mm,平均直径 4~6μm;所述钢纤维平均长度1~3mm,平均直径 40~180μm;所述硅酸铝纤维平均长度3~5 mm,平均直径5~10μm;所述的填料和摩擦性能调节剂为石墨、氧化铝、硅藻土、大理石、绿粉、黄粉、硫酸铝、促进剂、乳胶中的三种或三种以上混合物。
作为优选,所述的高性能复合摩擦材料的制备方法,包括如下操作步骤:
第一步:抄造陶瓷材料面层,将氧化铝纤维、钢纤维、硅酸铝纤维及填料和摩擦性能调节剂配比加料混合,接着通过高频疏解机疏解后制成厚度1.0mm 左右的陶瓷材料面层备用;
第二步:制备纸基复合纤维中间层,首先预处理碳纤维并制备柔性植物纤维原料,接着将预处理的碳纤维与柔性植物纤维、芳纶浆粕混合;加入摩擦粉、硅藻土等与浆料混合均匀;利用造纸用长网纸机湿法成型,成型后进行烘干备用;
第三步:将陶瓷材料面层和纸基复合纤维中间层共同浸胶,热压固化复合;
第四步:将钢板冲成摩擦盘片,经热处理高温氧化产生氧化皮、清洗油污、晾干;
第五步:将复合的陶瓷材料面层和纸基复合材料中间层在硫化机上与环形摩擦盘片高温高压复合,得到高性能复合摩擦材料。
作为优选,碳纤维的预处理方法是首先用丙酮抽提20h~26h,除去碳纤维表面的胶质和杂质,接着通过清水洗净后烘干,再用质量分数为50%的浓硝酸对丙酮处理过的碳纤维进一步处理2h,温度为75℃,然后再次清洗后,加入无水乙醇和硅烷偶联剂乙烯基三乙氧基硅烷搅拌1h。
作为优选,在造纸用长网纸机上,上网浓度为1.0%~3.5%,烘道温度为180~250℃。
作为优选,陶瓷材料和纸基复合材料的浸胶采用真空浸渍1h、常压浸渍2h的方式进行,胶液选取改性酚醛树脂的酒精溶液,浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,烘干温度 80~120 ℃,时间1.5h~3h,同时浸胶量控制在25%~35%。
作为优选,采用硫化机在高温高压下将浸胶后的面层和中间层与摩擦盘片高温热压复合,热压温度180 ℃,压力为15~20MPa,高温热压复合时间为5~10min。
本发明能够达到如下效果:
本发明提供了一种高性能复合摩擦材料及其制备方法,与现有技术相比较,具有操作方便、成本相对低廉、摩擦系数稳定、磨损率低和耐热系数高的优点。解决了使用寿命短的问题。实现了两种摩擦材料在性能方面的优势互补。
将陶瓷基摩擦材料与纸基复合材料进行复合,发挥陶瓷摩擦材料耐高温、抗氧化、耐磨损及热稳定性好的优势,解决单一纸基材料摩擦稳定性差、热衰退率高方面的问题,另一方面,利用纸基复合材料回弹性能好的特点,弥补陶瓷基摩擦材料韧性差、脆方面的缺陷,实现了两种摩擦材料在性能方面的优势互补。同时在造纸法抄造纸基复合材料中间层时,对短切碳纤维进行预处理,提高碳纤维的表面亲水性,提高其在水中的分散性,从而使碳纤维更好的发挥增强作用,制备出的纸基复合材料具有更好的力学性能、耐热性能及耐摩擦磨损性能。
具体实施方式
下面通过实施例,对发明的技术方案作进一步具体的说明。
实施例1:
1.抄造陶瓷材料面层,按照氧化铝纤维50%,钢纤维15%,硅酸铝纤维15%,填料和摩擦性能调节剂20%的配比加料,疏解后制成厚度1.0 mm 左右的陶瓷材料面层备用;
2.将马尾松和棉浆浆板浸泡过夜,在槽式打浆机中分别打浆,将马尾松打至35 °SR,棉浆打至28°SR。称取打好的25kg木浆和30kg棉浆疏解、混合均匀,加入8 kg预处理后的碳纤维及4 kg对位芳纶浆粕,再次疏解、混合均匀,再加入摩擦性能调节剂2.0kg,硅藻土4.0kg,颜料及硫酸铝各1.0kg,搅拌均匀后,通过管道流送到纸机,控制上网浓度3.0%。车速6m/min。利用烘道200℃烘干后裁切成一定规格。
3.将烘干后的陶瓷材料面层和纸基复合材料中间层置于真空浸胶器,胶液选取腰果壳改性酚醛树脂的50%酒精溶液,真空浸渍1h,真空度0.1Pa,常压浸渍2h。浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,一段烘干80 ℃,时间为1.5 h;第二段烘干120 ℃,时间为1.5h,浸胶量控制在32%。
4.将钢板按一定规格冲成摩擦盘片,摩擦盘片先使用冲床冲内外圆,再以外圆定位,根据钢芯板厚度调整热平整温度,700℃左右进行热平整,保温2h后进行热处理,淬硬至表面硬度HRC35~45,振动去氧化皮,在清洗机上进行清洗,去净表面油污,晾干。
5.将复合的陶瓷材料面层和纸基复合材料中间层在平板硫化机上与环形摩擦盘片高温热压复合,热压温度180℃,压力为18 MPa,时间为8 min,得到高性能复合摩擦材料。
实施例2:
1. 抄造陶瓷材料面层,按照氧化铝纤维40%,钢纤维20%,硅酸铝纤维20%,填料和摩擦性能调节剂20%的配比加料,疏解后制成厚度1.0 mm左右的陶瓷材料面层备用。
2. 将马尾松和棉浆浆板浸泡过夜,在槽式打浆机中分别打浆,将马尾松打至32°SR,棉浆打至30°SR。称取打好的28 kg木浆和32 kg棉浆疏解、混合均匀,加入8 kg预处理后的碳纤维及4 kg对位芳纶浆粕,再次疏解、混合均匀,再加入摩擦性能调节剂2.0 kg,硅藻土4.0 kg,颜料及硫酸铝各1.0 kg,搅拌均匀后,通过管道流送到纸机,控制上网浓度3.0%。车速6 m/min。利用烘道200 ℃烘干后裁切成一定规格。
3. 将烘干后的陶瓷材料面层和纸基复合材料中间层置于真空浸胶器,胶液选取腰果壳改性酚醛树脂的50%酒精溶液,真空浸渍1h,真空度0.1Pa,常压浸渍2h。浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,一段烘80 ℃,时间为1.5 h;第二段烘干120℃,时间为1.5h,浸胶量控制在32%。
4. 将钢板按一定规格冲成摩擦盘片,摩擦盘片先使用冲床冲内外圆,再以外圆定位,根据钢芯板厚度调整热平整温度,700℃左右进行热平整,保温2.5 h后进行热处理,淬硬至表面硬度HRC35~45,振动去氧化皮,在清洗机上进行清洗,去净表面油污,晾干。
5. 将复合的陶瓷材料面层和纸基复合材料中间层在平板硫化机上与环形摩擦盘片高温热压复合,热压温度180℃,压力为18 MPa,时间为8 min,得到高性能复合摩擦材料。
实施例3:
1. 抄造陶瓷材料面层,按照氧化铝纤维40%,钢纤维20%,硅酸铝纤维20%,填料和摩擦性能调节剂20%的配比加料,疏解后制成厚度 1.0 mm 左右的陶瓷材料面层备用。
2. 将马尾松和棉浆浆板浸泡过夜,在槽式打浆机中分别打浆,将马尾松打至32°SR,棉浆打至30°SR。称取打好的20 kg木浆和25 kg棉浆疏解、混合均匀,加入15 kg 预处理后的碳纤维及8 kg对位芳纶浆粕,再次疏解、混合均匀,再加入摩擦性能调节剂2.0 kg,硅藻土4.0 kg,颜料及硫酸铝各1.0 kg,搅拌均匀后,通过管道流送到纸机,控制上网浓度3.0%。车速6 m/min。利用烘道200℃烘干后裁切成一定规格。
3. 将烘干后的陶瓷材料面层和纸基复合材料中间层置于真空浸胶器,真空浸渍1h,真空度0.1Pa,常压浸渍2h。胶液选取腰果壳改性酚醛树脂的50%酒精溶液,浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,一段烘干80 ℃,时间为1.5h;第二段烘干120℃,时间为1.5h,浸胶量控制在32%。
4. 将钢板按一定规格冲成摩擦盘片,摩擦盘片先使用冲床冲内外圆,再以外圆定位,根据钢芯板厚度调整热平整温度,700℃左右进行热平整,保温2h后进行热处理,淬硬至表面硬度HRC35~45,振动去氧化皮,在清洗机上进行清洗,去净表面油污,晾干。
5. 将复合的陶瓷材料面层和纸基复合材料中间层在平板硫化机上与环形摩擦盘片高温热压复合,热压温度180 ℃,压力为18MPa,时间为8min,得到高性能复合摩擦材料。
实施例4:
1. 抄造陶瓷材料面层,按照氧化铝纤维40%,钢纤维20%,硅酸铝纤维20%,填料和摩擦性能调节剂20%的配比加料,疏解后制成厚度1.0 mm 左右的陶瓷材料面层备用。
2. 将棉浆浆板浸泡过夜,在槽式打浆机中分别打浆,将棉浆打至30°SR。称取打好的棉浆32 kg疏解、混合均匀,加入15 kg 预处理后的碳纤维及8 kg对位芳纶浆粕,再次疏解、混合均匀,再加入摩擦性能调节剂2.0 kg,硅藻土4.0 kg,颜料及硫酸铝各.0 kg,搅拌均匀后,通过管道流送到纸机,控制上网浓度3.0%。车速6 m/min。利用烘道200℃烘干后裁切成一定规格。
3. 将烘干后的陶瓷材料面层和纸基复合材料中间层置于真空浸胶器,真空浸渍1h,真空度0.1Pa,常压浸渍2 h。胶液选取腰果壳改性酚醛树脂的50%酒精溶液,浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,一段烘干80 ℃ ,时间为1.5 h,第二段烘干120℃,时间为1.5 h,浸胶量控制在32%。
4. 将钢板按一定规格冲成摩擦盘片,摩擦盘片先使用冲床冲内外圆,再以外圆定位,根据钢芯板厚度调整热平整温度,700 ℃左右进行热平整,保温2.5 h后进行热处理,淬硬至表面硬度HRC35~45,振动去氧化皮,在清洗机上进行清洗,去净表面油污,晾干。
5. 将复合的陶瓷材料面层和纸基复合材料中间层在平板硫化机上与环形摩擦盘片高温热压复合,热压温度180 ℃,压力为18MPa,时间为8min,得到高性能复合摩擦材料。
实施例5:
1. 抄造陶瓷材料面层,按照氧化铝纤维40%,钢纤维20%,硅酸铝纤维20%,填料和摩擦性能调节剂20%的配比加料,疏解后制成厚度1.0 mm左右的陶瓷材料面层备用。
2. 将马尾松和棉浆浆板浸泡过夜,在槽式打浆机中分别打浆,将马尾松打至31°SR,棉浆打至28 °SR。称取打好的25 kg木浆和30 kg棉浆疏解、混合均匀,加入10 kg预处理后的短切碳纤维及4 kg对位芳纶浆粕,再次疏解、混合均匀,再加入摩擦性能调节剂2.0kg,硅藻土4.0 kg,颜料及硫酸铝各1.0 kg,搅拌均匀后,通过管道流送到纸机,控制上网浓度3.0%。车速6 m/min。利用烘道200 ℃烘干后裁切成一定规格。
3. 将烘干后的陶瓷材料面层和纸基复合材料中间层置于真空浸胶器,真空浸渍1.5h,真空度0.1Pa,常压浸渍1.5h。胶液选取丁腈橡胶改性酚醛树脂的50%酒精溶液,浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,一段烘干80 ℃,时间为1 h;第二段烘干120℃,时间为1.5 h,浸胶量控制在32%。
4. 将钢板按一定规格冲成摩擦盘片,摩擦盘片先使用冲床冲内外圆,再以外圆定位,根据钢芯板厚度调整热平整温度,700 ℃左右进行热平整,保温2h后进行热处理,淬硬至表面硬度HRC35~45,振动去氧化皮,在清洗机上进行清洗,去净表面油污,晾干。
5. 将复合的陶瓷材料面层和纸基复合材料中间层在平板硫化机上与环形摩擦盘片高温热压复合,热压温度200℃,压力为18MPa,时间为8min,得到高性能复合摩擦材料。
实施例6:
1. 抄造陶瓷材料面层,按照氧化铝纤维40%,钢纤维20%,硅酸铝纤维20%,填料和摩擦性能调节剂20%的配比加料,疏解后制成厚度1.0 mm 左右的陶瓷材料面层备用。
2. 将马尾松和棉浆浆板浸泡过夜,在槽式打浆机中分别打浆,将马尾松打至32°SR,棉浆打至30 °SR。称取打好的28 kg木浆和32 kg棉浆疏解、混合均匀,加入12 kg 预处理后的碳纤维及4 kg对位芳纶浆粕,再次疏解、混合均匀,再加入摩擦性能调节剂2.0 kg,硅藻土4.0 kg,颜料及硫酸铝各1.0 kg,搅拌均匀后,通过管道流送到纸机,控制上网浓度3.0%。车速 6 m/min。利用烘道200 ℃烘干后裁切成一定规格。
3. 将烘干的陶瓷材料面层和纸基复合材料中间层置于真空浸胶器,真空浸渍1h,真空度0.1Pa,常压浸渍2h。胶液选取腰果壳改性酚醛树脂的50%酒精溶液,浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,一段烘干80 ℃,时间为1.5 h;第二段烘干120℃,时间为1.5h,浸胶量控制在32%。
4. 将钢板按一定规格冲成摩擦盘片,摩擦盘片先使用冲床冲内外圆,再以外圆定位,根据钢芯板厚度调整热平整温度,700 ℃左右进行热平整,保温2.5 h后进行热处理,淬硬至表面硬度HRC35~45,振动去氧化皮,在清洗机上进行清洗,去净表面油污,晾干。
5. 将复合的陶瓷材料面层和纸基复合材料中间层在平板硫化机上与环形摩擦盘片高温热压复合,热压温度180 ℃,压力为18MPa,时间为8min,得到高性能复合摩擦材料。
实施例7:
1. 抄造陶瓷材料面层,按照氧化铝纤维50%,钢纤维20%,硅酸铝纤维20%,填料和摩擦性能调节剂10%的配比加料,疏解后制成厚度1.0 mm 左右的陶瓷材料面层备用。
2. 将马尾松和棉浆浆板浸泡过夜,在槽式打浆机中分别打浆,将马尾松打至31°SR,棉浆打至28°SR。称取打好的28 kg木浆和32 kg棉浆疏解、混合均匀,加入8 kg 预处理后的短切碳纤维及4 kg对位芳纶浆粕,再次疏解、混合均匀,再加入摩擦性能调节剂3.0kg,硅藻土2.0 kg,颜料及硫酸铝各1.0 kg,搅拌均匀后,通过管道流送到纸机,控制上网浓度 2.5%。车速6 m/min。利用烘道200℃烘干后裁切成一定规格。
3. 将烘干的陶瓷材料面层和纸基复合材料中间层置于真空浸胶器,真空浸渍1h,真空度0.1Pa,常压浸渍2h。胶液选取腰果壳改性酚醛树脂的50%酒精溶液,浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,一段烘干80 ℃,时间为1.5 h;第二段烘干120 ℃,时间为1.5h,浸胶量控制在30%。
4. 将钢板按一定规格冲成摩擦盘片,摩擦盘片先使用冲床冲内外圆,再以外圆定位,根据钢芯板厚度调整热平整温度,650 ℃左右进行热平整,保温2h后进行热处理,淬硬至表面硬度HRC35~45,振动去氧化皮,在清洗机上进行清洗,去净表面油污,晾干。
5. 将复合的陶瓷材料面层和纸基复合材料中间层在平板硫化机上与环形摩擦盘片高温热压复合,热压温度180℃,压力为18MPa,时间为8min,得到高性能复合摩擦材料。
实施例8:
1. 抄造陶瓷材料面层,按照氧化铝纤维60%,钢纤维10%,硅酸铝纤维10%,填料和摩擦性能调节剂15%的配比加料,疏解后制成厚度1.0 mm 左右的陶瓷材料面层备用。
2. 将马尾松和棉浆浆板浸泡过夜,在槽式打浆机中分别打浆,将马尾松打至32°SR,棉浆打至 30°SR。称取打好的28 kg木浆和32 kg棉浆疏解、混合均匀,加入8 kg 预处理后的短切碳纤维及4 kg对位芳纶浆粕,再次疏解、混合均匀,再加入摩擦性能调节剂2.0kg,硅藻土4.0 kg,颜料及硫酸铝各1.0 kg,搅拌均匀后,通过管道流送到纸机,控制上网浓度3.0%。车速6 m/min。利用烘道200 ℃烘干后裁切成一定规格。
3. 将烘干后的陶瓷材料面层和纸基复合材料中间层置于真空浸胶器,胶液选取丁腈橡胶改性酚醛树脂的50%酒精溶液,真空浸渍1h,真空度0.1Pa,常压浸渍2h。浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,一段烘干80 ℃,时间为1.5 h;第二段烘干120℃,时间为1.5h,浸胶量控制在32%。
4. 将钢板按一定规格冲成摩擦盘片,摩擦盘片先使用冲床冲内外圆,再以外圆定位,根据钢芯板厚度调整热平整温度,700℃左右进行热平整,保温2.5 h后进行热处理,淬硬至表面硬度HRC35~45,振动去氧化皮,在清洗机上进行清洗,去净表面油污,晾干。
5. 将复合的陶瓷材料面层和纸基复合材料中间层在平板硫化机上与环形摩擦盘片高温热压复合,热压温度180 ℃,压力为18MPa,时间为8min,得到高性能复合摩擦材料。
综上所述,该高性能复合摩擦材料及其制备方法,具有操作方便、成本相对低廉、摩擦系数稳定、磨损率低和耐热系数高的优点。解决了使用寿命短的问题。实现了两种摩擦材料在性能方面的优势互补。
以上所述仅为本发明的具体实施例,但本发明的结构特征并不局限于此,任何本领域的技术人员在本发明的领域内,所作的变化或修饰皆涵盖在本发明的专利范围之中。
Claims (9)
1.一种高性能复合摩擦材料,其特征在于:包括纸基复合材料中间层,所述的纸基复合材料中间层上端设有陶瓷材料面层,所述的纸基复合材料中间层下端设有环形摩擦盘片底层;所述的陶瓷材料面层包含以下质量百分比的原料:氧化铝纤维40%~60%;钢纤维15%~30%;硅酸铝纤维15%~30%;填料和摩擦性能调节剂10%~30%。
2.根据权利要求1所述的高性能复合摩擦材料,其特征在于:所述的纸基复合材料中间层包含以下质量百分比的组分:柔性植物纤维40%~60%;芳纶浆粕5%~10%;碳纤维10%~20%;摩擦粉2%~8%;填料及添加剂 15%~30%;改性酚醛树脂20%~40%。
3.根据权利要求2所述的高性能复合摩擦材料,其特征在于:所述的碳纤维的宽度为1~3 mm,长度为8~15 mm;所述的柔性植物纤维包括针叶木浆、阔叶木浆、棉浆中的一种或几种;其中针叶木浆和阔叶木浆打浆度为25~35°SR,纤维长度1.5~5mm,宽25~40μm;棉浆打浆度为20~30°SR,纤维长度1~5mm,宽20~35μm;所述的芳纶浆粕长度0.5~2 mm,宽 25~20μm。
4.根据权利要求1所述的高性能复合摩擦材料,其特征在于:所述的氧化铝纤维平均长度 2~5mm,平均直径 4~6μm;所述钢纤维平均长度1~3mm,平均直径 40~180μm;所述硅酸铝纤维平均长度3~5 mm,平均直径5~10μm;所述的填料和摩擦性能调节剂为石墨、氧化铝、硅藻土、大理石、绿粉、黄粉、硫酸铝、促进剂、乳胶中的三种或三种以上混合物。
5.根据权利要求3所述的高性能复合摩擦材料的制备方法,其特征在于包括如下操作步骤:
第一步:抄造陶瓷材料面层,将氧化铝纤维、钢纤维、硅酸铝纤维及填料和摩擦性能调节剂配比加料混合,接着通过高频疏解机疏解后制成厚度1.0mm 左右的陶瓷材料面层备用;
第二步:制备纸基复合纤维中间层,首先预处理碳纤维并制备柔性植物纤维原料,接着将预处理的碳纤维与柔性植物纤维、芳纶浆粕混合;加入摩擦粉、硅藻土等与浆料混合均匀;利用造纸用长网纸机湿法成型,成型后进行烘干备用;
第三步:将陶瓷材料面层和纸基复合纤维中间层共同浸胶,热压固化复合;
第四步:将钢板冲成摩擦盘片,经热处理高温氧化产生氧化皮、清洗油污、晾干;
第五步:将复合的陶瓷材料面层和纸基复合材料中间层在硫化机上与环形摩擦盘片高温高压复合,得到高性能复合摩擦材料。
6.根据权利要求5所述的高性能复合摩擦材料的制备方法,其特征在于:碳纤维的预处理方法是首先用丙酮抽提20h~26h,除去碳纤维表面的胶质和杂质,接着通过清水洗净后烘干,再用质量分数为50%的浓硝酸对丙酮处理过的碳纤维进一步处理2h,温度为75℃,然后再次清洗后,加入无水乙醇和硅烷偶联剂乙烯基三乙氧基硅烷搅拌1h。
7.根据权利要求5所述的高性能复合摩擦材料的制备方法,其特征在于:在造纸用长网纸机上,上网浓度为1.0%~3.5%,烘道温度为180~250℃。
8.根据权利要求5所述的高性能复合摩擦材料的制备方法,其特征在于:陶瓷材料和纸基复合材料的浸胶采用真空浸渍1h、常压浸渍2h的方式进行,胶液选取改性酚醛树脂的酒精溶液,浸胶后材料经自然晾干至酒精挥发后,利用烘箱烘干,烘干温度 80~120 ℃,时间1.5h~3h,同时浸胶量控制在25%~35%。
9.根据权利要求5所述的高性能复合摩擦材料的制备方法,其特征在于:采用硫化机在高温高压下将浸胶后的面层和中间层与摩擦盘片高温热压复合,热压温度180 ℃,压力为15~20MPa,高温热压复合时间为5~10min。
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