CN112143921B - Preparation method for preparing aluminum matrix composite brake disc - Google Patents

Preparation method for preparing aluminum matrix composite brake disc Download PDF

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Publication number
CN112143921B
CN112143921B CN202011009039.1A CN202011009039A CN112143921B CN 112143921 B CN112143921 B CN 112143921B CN 202011009039 A CN202011009039 A CN 202011009039A CN 112143921 B CN112143921 B CN 112143921B
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aluminum
brake disc
manufacturing
matrix composite
based composite
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CN112143921A (en
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谭东
夏少华
李向平
张剑云
李娄明
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CRRC Qishuyan Institute Co Ltd
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CRRC Qishuyan Institute Co Ltd
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Priority to CN202011009039.1A priority Critical patent/CN112143921B/en
Publication of CN112143921A publication Critical patent/CN112143921A/en
Priority to PCT/CN2021/119478 priority patent/WO2022063099A1/en
Priority to MX2023003366A priority patent/MX2023003366A/en
Priority to CN202180065279.XA priority patent/CN116348234A/en
Priority to US18/028,003 priority patent/US20230349435A1/en
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • C22C1/026Alloys based on aluminium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D1/00Treatment of fused masses in the ladle or the supply runners before casting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00Pressure casting; Vacuum casting
    • B22D18/04Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/06Making non-ferrous alloys with the use of special agents for refining or deoxidising
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent
    • C22C21/04Modified aluminium-silicon alloys
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C32/00Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C22C32/0052Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Braking Arrangements (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

The invention provides a preparation method for preparing an aluminum matrix composite brake disc, which comprises the following steps: aluminum material preparation step S1: baking the aluminum material; an aluminum material melting step S2: completely melting the baked aluminum material; melt forming step S3: adding alloying materials into the aluminum liquid to form a melt; mechanical stirring step S4: mechanically stirring the melt; reinforcing particle addition step S5: adding the reinforced particles into the melt, and performing accelerated mechanical stirring; rolling step S6: rolling the melt into a plate under a vacuum condition; friction stir processing step S7: and (3) carrying out friction stir processing on the aluminum-based composite plate and a brake disc blank prepared in advance to combine the aluminum-based composite plate and the brake disc blank. The invention can improve the ceramic particle fraction on the surface of the aluminum-based composite material, increase the wear resistance, improve the elongation rate, reduce the failure risk, increase the thermal diffusion coefficient, transfer the heat generated by the friction layer and reduce the temperature rise, and the matrix has no ceramic particles.

Description

Preparation method for preparing aluminum matrix composite brake disc
Technical Field
The invention relates to the field of brake discs, in particular to a preparation method for preparing an aluminum matrix composite brake disc.
Background
With the increasing environmental pressure, energy conservation, emission reduction and environmental pollution reduction become the basic national policies of the present day. The weight of the rail transit vehicle is reduced, and energy consumption and emission caused by frequent starting and braking are reduced, so that the method is one of the most effective methods for realizing energy conservation and emission reduction. One of the main approaches to reduce the weight of rail transit vehicles at present is to use a brake disc made of a novel light material to replace a traditional brake disc made of steel or iron material, so as to reduce the weight of the material of unsprung parts of the running vehicle and maintain an ideal unsprung weight ratio of the sprung part to the unsprung part. The existing brake disc made of light materials mainly comprises a brake disc made of carbon/carbon fiber composite materials, ceramic composite materials and aluminum matrix composite materials. Among them, the research on the brake disc made of the ceramic particle reinforced aluminum matrix composite material is relatively extensive.
The brake disc made of the existing aluminum-based composite material is mainly a brake disc made of a ceramic particle reinforced aluminum-based composite material, such as a brake disc made of a SiC particle reinforced aluminum-based composite material, and the whole brake disc is made of the same material. The alloy is mainly prepared by a vacuum stirring casting method. The aluminum matrix composite brake disc prepared by the method has the following technical problems:
firstly, when the aluminum matrix composite is prepared by a vacuum stirring casting method, although the wear resistance of the aluminum matrix composite brake disc can be improved by increasing the adding amount of the ceramic particles, the toughness can be reduced to influence the comprehensive mechanical property of the aluminum matrix composite brake disc, and the forming property of the aluminum matrix composite is influenced to cause the defects of insufficient pouring or air hole slag inclusion. In view of the above reasons, the ceramic particle addition amount of the ceramic particle reinforced aluminum matrix composite brake disc prepared by the vacuum stirring casting method in the prior art is about 20%, and the requirement of wear resistance is difficult to meet.
Second, a large investment is required due to the use of an expensive vacuum agitation manufacturing apparatus.
Thirdly, the vacuum stirring casting equipment has higher requirements on the process control level, and the prepared ceramic particle reinforced aluminum matrix composite brake disc is easy to generate defects of air holes, slag inclusion, ceramic particle segregation and the like.
In the prior art, patent CN1298457C discloses a vacuum mechanical double-stirring casting method, aluminum materials are melted and cleaned, cooled and deslagged; the method comprises the following steps of (1) completing a degassing process by reverse slow internal stirring under vacuum, adding pretreated reinforcing particles to the surface of molten aluminum after deslagging, simultaneously stirring in the internal and external positive directions, winding the reinforcing particles into a melt, stopping external stirring, under the condition of keeping the liquid level stable, uniformly distributing the reinforcing particles in the liquid by high-speed internal stirring, heating, and then completing the degassing process by internal and external reverse double-stirring slow rotation; adding a modifier and a refiner, and melting the modifier and the refiner into the melt by internal stirring and slow rotation and uniformly distributing the modifier and the refiner; and (4) unloading the vacuum, discharging the furnace and casting into a cast ingot.
The method does not screen the size of the reinforced particles, the randomness of the size of the reinforced particles is large, and the prepared aluminum-based composite material is not suitable for processing brake discs. The reason is that the wear resistance and the braking performance of the brake disc of the whole vehicle are required to be consistent, and the performance of the brake disc of the aluminum-based composite material prepared based on the method is not stable enough when the aluminum-based composite material is used for the brake disc.
Disclosure of Invention
The main object of the present invention is to provide a method for manufacturing a brake disc made of an aluminum matrix composite, so as to solve the above problems in the prior art.
In order to achieve the above object, according to one aspect of the present invention, there is provided a manufacturing method for manufacturing an aluminum matrix composite brake disc, including the steps of:
an aluminum material melting step S2: completely melting the aluminum material to form aluminum liquid;
melt forming step S3: adding alloying materials into the aluminum liquid to form a melt;
mechanical stirring step S4: mechanically stirring the melt;
reinforcing particle addition step S5: adding the reinforced particles into the melt, and performing accelerated mechanical stirring;
rolling step S6: rolling the melt into an aluminum-based composite plate under a vacuum condition;
friction stir processing step S7: and (3) carrying out friction stir processing on the aluminum-based composite plate and a brake disc blank prepared in advance, and combining the aluminum-based composite plate and the brake disc blank together.
Further, a reinforcing particle screening step Z1 is included before the reinforcing particle adding step S5: and (3) screening the enhanced particles.
Further, in the reinforced particle screening step Z1, reinforced particles with the particle size of 10-40 μm and the normal distribution value of 10-30 μm are screened out.
Further, the reinforcing particles are SiC particles.
Further, between the reinforcing particle adding step S5 and the reinforcing particle screening step Z1, a reinforcing particle roasting pretreatment step Z2: and (3) carrying out roasting pretreatment on the reinforced particles to remove surface impurities and adsorb moisture.
Further, the reinforcing particle firing pretreatment step Z2 includes a step of forming a SiO2 oxide film on the surface of the SiC particles as the reinforcing particles.
Further, the reinforcing particles are added in the step S5, wherein the adding speed of the reinforcing particles is 2-5 g/S.
Further, before the melt forming step S3, the method includes a modifier and refiner weighing step X1: weighing alterant and refiner based on the weight ratio of aluminum material.
Further, between the melt forming step S3 and the alterant and refiner weighing step X1, the method comprises a step X3 of adding the alterant and the refiner into the aluminum liquid to form the melt.
Further, between the step of weighing the alterant and the refiner X1 and the step of adding the alterant and the refiner into the aluminum liquid X3, the method comprises a baking step X2: baking the alterant and the refiner to remove water.
Further, before the aluminum material melting step S2, an aluminum material preparation step S1 is included: baking the aluminum material and removing moisture.
Further, the friction stir processing step S6 includes a mixing step S61 and a cooling step S62, and in the mixing step S61, the portions of the brake disc blank and the aluminum-based composite plate that are in contact with each other are sufficiently mixed together; in the cooling step S62, a brake disk having a transition layer is formed.
Further, in the friction stir processing step S6, the rotation speed of the friction stir processing is 600-1200 rpm, and the feed speed is 100-500 mm/min.
Further, in the reinforced particle roasting pretreatment step S3, the roasting pretreatment temperature is 400-1000 ℃.
Further, in the mechanical stirring step S4, the rotation speed of the motor is controlled to be 500-600 rpm.
Further, in the friction stir processing step S6, a transition layer is generated between the aluminum-based composite plate and the brake disc blank.
Furthermore, the tensile strength Rm of the aluminum-based composite plate is more than or equal to 140MPa, the elongation A after fracture is more than or equal to 0.5 percent, and the hardness is more than or equal to 65 HBW.
Further, the transition layer has a spherical or spheroidal silicon phase therein.
Furthermore, the length of the silicon phase is less than or equal to 10 μm, and the sphericity of the silicon phase is 20-100%.
By applying the technical scheme of the invention, the beneficial effects are as follows:
1. the aluminum matrix composite brake disc prepared by the preparation method provided by the invention has the advantages that the ceramic particle fraction on the surface of the aluminum matrix composite is improved, the wear resistance is improved, compared with vacuum stirring casting, the brake disc matrix is not added with ceramic particles, the comprehensive mechanical properties such as the elongation of the matrix can be effectively improved, the failure risk is reduced, the thermal diffusion coefficient of the brake disc is increased, the heat generated by a friction layer can be transferred out, and the temperature rise of the brake disc is reduced.
2. In the prior art, the aluminum matrix composite brake disc prepared by vacuum stirring casting integrally adopts the same ceramic particle reinforced aluminum matrix composite, and during the preparation process, the ceramic particles are easy to generate segregation defects in the aluminum matrix composite, so that the mechanical property of the brake disc is poor; compared with the prior art, the ceramic particles of the aluminum matrix composite brake disc prepared by the preparation method provided by the invention are more uniformly distributed, and the prepared aluminum matrix composite brake disc has good wear resistance and toughness.
3. In the prior art, in the aluminum matrix composite brake disc prepared by vacuum stirring casting, the adding amount of the ceramic particles is limited, because the adding of the ceramic particles can improve the wear resistance but can reduce the toughness. Therefore, the addition amount of the ceramic particles in the brake disc made of the aluminum matrix composite material prepared by the prior art is about 20 percent, so that the brake disc is ensured to have wear resistance and not too low in toughness. Compared with the prior art, the aluminum matrix composite brake disc prepared by the invention has more uniform internal structure, when the addition of the ceramic particles exceeds 20%, the added ceramic particles exist near the transition layer, and the brake disc as a whole still has good toughness, can improve the wear resistance and has better overall mechanical property.
4. Compared with the defects that the existing vacuum stirring casting method is easy to generate air holes, impurities and the like, the aluminum matrix composite brake disc prepared by the preparation method provided by the invention has more uniform tissue, fewer defects and no defects of air holes, impurities and the like, so that the aluminum matrix composite brake disc has better mechanical properties compared with the aluminum matrix composite brake disc in the prior art.
5. Compared with the prior art, the vacuum stirring casting equipment with high price is not adopted, so that the production cost is greatly reduced.
6. In the prior art, the vacuum stirring casting process needs to be carried out at high temperature, and operators may have operation safety risk during operation, while the stirring friction processing process is carried out at non-high temperature, so that the process is simplified and the safety of process operation is ensured.
7. In the preparation method, the prepared aluminum-based composite board is specially used for preparing the brake disc, compared with the prior art, the size of the reinforced particles is screened, the reinforced particles are normally distributed, and the large particles are beneficial to improving the braking performance of the brake disc; the small particles can improve the wear resistance of the brake disc, thereby improving the overall mechanical property of the brake disc.
8. In the preparation method, in the process of preparing the aluminum-based composite board, the reinforced particles are treated by adopting roasting pretreatment, so that a layer of SiO2 oxide film can be formed, the wettability between the reinforced particles and the aluminum-based composite material is increased, and the performance of the composite material is improved, thereby meeting the requirement of the aluminum-based composite board for a brake disc.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 shows a schematic diagram of a process route of the present invention;
FIG. 2 shows a schematic view of the composite layer, transition layer and substrate layer structure of the present invention;
FIG. 3 shows a schematic representation of a cross-sectional view of a composite layer, a transition layer, and a substrate layer of the present invention;
FIG. 4 shows a metallographic structure of an aluminum-based composite brake disc without friction stir processing;
fig. 5 shows a metallographic structure of an aluminum composite brake disc that is not subjected to friction stir processing.
Detailed Description
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
The present application is described in further detail below with reference to specific examples, which should not be construed as limiting the scope of the invention as claimed.
Referring to fig. 1, the method for manufacturing the brake disc made of the aluminum matrix composite according to the present invention is implemented according to the following steps:
s1: preparing an aluminum material. An aluminum matrix composite is used as a raw material. In this embodiment, the aluminum-based composite material is an aluminum-based composite material in which ceramic particles such as SiC, TiN, or BN are added to aluminum copper, aluminum silicon, or an aluminum magnesium alloy. First, an aluminum material is prepared.
X1: and weighing the alterant and the refiner. Weighing the quality of the alterant and the refiner according to the weight ratio of the aluminum material.
X2: and (5) baking. And putting the weighed aluminum material, the alterant and the refiner into an oven for baking to remove moisture.
Z1: and (4) enhancing particle screening. And sieving the reinforced particles, removing agglomerated particle groups and other impurities, and screening out the reinforced particles with the SiC particle size of 10-40 mu m and the normal distribution value of 10-30 mu m.
Z2: and (3) carrying out roasting pretreatment on the reinforced particles. And (3) placing the sieved enhanced particles into an oven for roasting pretreatment at the temperature of 300-400 ℃ to remove surface impurities and adsorb moisture. Meanwhile, a layer of SiO2 oxide film is formed on the surface of the SiC particles, so that the contact wettability of the SiC particles and an aluminum matrix is improved.
S2: and melting the aluminum material. Heating the baked aluminum material to 700-800 ℃ in a vacuum environment to completely melt the aluminum liquid.
X2: adding a modifier and a refiner into the aluminum liquid. After the aluminum materials are completely melted at high temperature, the modifier and the refiner which are baked and have water removed and the alloying materials are added into the completely melted aluminum liquid.
S3: adding alloying material, modifier and refiner into the molten aluminum to form a melt gradually. Introducing argon gas into the molten aluminum for degassing and refining while adding the alloying material, the alterant and the refiner, removing water vapor and impurities in the melt, and effectively purifying the melt, wherein the degassing and refining time is 15-30 minutes.
S4: and (5) after degassing is finished, starting mechanical stirring of the melt, wherein the rotating speed of the motor is 500-600 rpm.
S5: a step of adding reinforcing particles. And while mechanically stirring the melt, adding the pretreated SiC particles into the melt at a constant speed, wherein the adding speed of the SiC particles is 2-5g/s, adjusting the rotating speed of a motor to 800 r/min after the SiC powder is completely added, and stirring and homogenizing the SiC particles in the melt.
S6: when the SiC particles are fully dispersed and uniformly distributed in the melt, controlling the temperature of the melt to be 700-720 ℃, and rolling the melt into a plate under the vacuum condition, thereby preparing the SiC particle reinforced aluminum matrix composite plate. The performance of the aluminum-based composite layer plate prepared by the invention is as follows: rm is more than or equal to 200MPa, elongation is more than or equal to 0.5, and hardness is more than or equal to 80 HB.
S7: and (3) carrying out friction stir processing on the aluminum-based composite plate and a brake disc blank prepared in advance, and combining the aluminum-based composite plate and the brake disc blank together. And (3) carrying out friction stir processing on the surface of the composite structure of the brake disc blank and the aluminum-based composite plate, wherein the surface refers to the upper surface of the aluminum-based composite plate, but not the lower surface which is in contact with the brake disc blank. The friction stir processing specifically includes two steps, a mixing step S71 and a cooling step S72 after the mixing step.
The mixing step S71 is a step of mixing the portions of the brake disc blank and the aluminum-based composite plate that are in contact with each other, and the cooling step S72 is a step of cooling the portions of the brake disc blank and the aluminum-based composite plate that are in contact with each other after mixing, and during the cooling step, a transition layer is formed between the brake disc blank and the aluminum-based composite plate to obtain an aluminum-based composite brake disc having a transition layer, the transition layer being formed of the mixed portions.
In the process of the friction stir processing, the stirring speed of the friction stir processing is 600-. The friction stir processing tool comprises a stirring head, the stirring head is utilized to rotate at a high speed to heat the surface of the aluminum-based composite plate to a plastic state, and SiC particles in the small holes are extruded and brought into the aluminum-based composite plate. Meanwhile, a transition layer is generated between the aluminum-based composite plate and the brake disc blank in the friction stir processing process, so that the brake disc blank and the aluminum-based composite plate can be combined together. This bonding is a metallurgical bonding. In the stirring friction processing process, original dendritic crystals near the contact surface of the brake disc blank and the aluminum-based composite plate are broken, and a structure with smaller and more uniform grain sizes is obtained. Therefore, the bonding force between the brake disc blank and the aluminum-based composite plate is strengthened.
S8: and (5) removing the blank seam on the surface of the brake disc prepared in the step (S7) to finish the machining of the reference surface of the brake disc.
The preparation steps of the brake disc blank prepared in advance are as follows:
and forming a brake disc blank by adopting an aluminum-silicon alloy or an aluminum-silicon-copper alloy as a matrix alloy through a casting forming process. Firstly, aluminum-silicon alloy or aluminum-silicon-copper alloy or aluminum-silicon (copper) alloy containing a small amount of ceramic particles is used as matrix alloy to form an aluminum ingot, and an aluminum-strontium alloy modifier and an aluminum-titanium-boron refiner are weighed according to the weight of the aluminum ingot. And then, putting the aluminum ingot, the aluminum-strontium alloy modifier and the aluminum-titanium-boron refiner into an oven for baking to remove moisture. And heating the dried aluminum ingot to 700-800 ℃, adding an aluminum strontium alloy modifier, a refining agent and an aluminum titanium boron refiner into the aluminum ingot when the aluminum ingot is completely melted, and introducing argon into the melted aluminum liquid for degassing for 30-50 minutes. Controlling the temperature of the aluminum liquid at 700-720 ℃, and pouring the brake disc blank by using a special metal mold for the brake disc through low-pressure pouring, wherein the pouring process comprises liquid rising, mold filling, crusting, pressure maintaining and pressure relief. And finally, opening the die and taking out the aluminum alloy brake disc blank casting. And (4) preliminarily processing the base layer according to the profile size of the disc surface of the brake disc to obtain a brake disc blank.
The main part of the brake disc is a brake disc blank, which has higher requirement on strength. The brake disc blank prepared by the method has the advantages that the refiner, the refining agent and the modifier are added into the aluminum liquid, so that the formed aluminum ingot has more uniform tissue and enough strength, and the failure risks such as deformation, cracks and the like in the use process can be reduced. The properties of the brake disc blank prepared by the method are as follows: rm is more than or equal to 230MPa, the elongation is more than or equal to 2, and the hardness is more than or equal to 90 HB.
The brake disc prepared by the method is prepared by friction stir processing of a brake disc blank made of two different materials and an aluminum-based composite layer plate. The stirring friction processing can improve the defects of air holes, slag inclusion and the like in the prepared aluminum-based composite layer plate, and can improve the mechanical property of the aluminum-based composite layer plate, thereby improving the overall mechanical property of the brake disc.
Wherein, the brake disc blank is aluminum-silicon alloy or aluminum-silicon-copper alloy and mainly plays a bearing role. The aluminium-silicon alloy or the aluminium-silicon-copper alloy may be a hypoeutectic alloy or a eutectic alloy or a hypereutectic alloy. A small amount of ceramic particles can be added into the brake disc blank to improve the mechanical property, the impact resistance and the high-temperature resistance of the brake disc blank. The aluminum-based composite layer plate is an aluminum-based composite material containing ceramic particles, and has good frictional wear performance, so that the aluminum-based composite layer plate has the function of providing frictional braking force. The aluminum-based composite material is an aluminum-based composite material obtained by adding ceramic particles such as SiC, TiN or BN to aluminum copper, aluminum silicon or aluminum magnesium alloy. Preferably, , any one or more of zirconium, lanthanum and cerium are added into the aluminum-based composite material to prepare the aluminum-based composite plate, so that the performance of the aluminum-based composite plate can be improved. The thickness of the aluminum-based composite plate is 3-10 mm.
And (3) forming a transition layer at the contact part of the aluminum-based composite layer plate in the brake disc and the brake disc blank by friction stir processing. Macroscopically, the transition layer consists of an aluminum-based composite plate and a brake disc blank. In the cross-sectional interface diagrams of the brake disc made of the aluminum-based composite material, as shown in fig. 2 and 3, the transition layer comprises a strengthening structure, so that the bonding force between the aluminum-based composite plate and the brake disc blank can be increased. The reinforcing structure refers to a boundary surface where the aluminum-based composite material and the brake disc blank enter each other after friction stir processing, and is a boundary line of the two materials in fig. 2 and 3. FIG. 2 is a schematic view of a composite layer, transition layer and substrate layer structure prepared using the above method; FIG. 3 is a schematic representation of a cross-sectional view of a composite layer, a transition layer, and a substrate layer made using the present invention. Such a reinforcing structure is a non-planar structure. Such non-planar structures are irregularly shaped structures. Preferably, such irregularly shaped structures are saw tooth and/or inverted trapezoidal and/or regular trapezoidal structures. The reinforced structure realizes the component transition between the reinforced blank of the brake disc and the aluminum-based composite plate. The reinforcing structure comprises a first reinforcing part and a second reinforcing part. The first reinforcing portion is a structure directed deep into the aluminum-based composite panel, as shown in fig. 2, exhibiting a convex-like shape. The material composition of the brake disc blank and the SiC particles increase in a gradient from the brake disc blank to the first reinforcing portion. From the first reinforcing part to the aluminum-based composite board, the material components and SiC particles of the aluminum-based composite board increase in a gradient manner. The second reinforcing portion is a structure that points deep into the brake disc blank, as shown in fig. 2, assuming a concave-like shape. From the aluminum-based composite board to the second reinforcing structure, the components of the aluminum-based composite material and SiC particles are reduced in a gradient manner. From the second reinforced part to the brake disc blank, the material composition of the brake disc blank increases in a gradient manner, and the SiC particles decrease in a gradient manner. The distance between the apex of the first reinforcing structure and the apex of the second reinforcing structure is the thickness of the transition layer. The thickness of the transition layer is 1-5 mm. The elongation of the transition layer is A more than or equal to 1 percent. From the microstructure, the size of the microscopic crystal of the transition layer is smaller than the size of the microscopic crystal particles of the brake disc blank and the aluminum-based composite plate. The length of the microscopic crystal particles of the transition layer is less than or equal to 10 mu m.
As can be seen by comparing fig. 4 and 5, the metallographic structure of the composite brake disc which is not subjected to stir casting has larger particles, as shown in fig. 5; the composite material brake disc processed by stirring casting has smaller metallographic structure particles.
From the above description, it can be seen that the above-described embodiments of the present invention achieve the following technical effects:
1. the aluminum matrix composite brake disc prepared by the preparation method provided by the invention has the advantages that the ceramic particle fraction on the surface of the aluminum matrix composite is improved, the wear resistance is improved, compared with vacuum stirring casting, the brake disc matrix is not added with ceramic particles, the comprehensive mechanical properties such as the elongation of the matrix can be effectively improved, the failure risk is reduced, the thermal diffusion coefficient of the brake disc is increased, the heat generated by a friction layer can be transferred out, and the temperature rise of the brake disc is reduced.
2. In the prior art, the aluminum matrix composite brake disc prepared by vacuum stirring casting integrally adopts the same ceramic particle reinforced aluminum matrix composite, and during the preparation process, the ceramic particles are easy to generate segregation defects in the aluminum matrix composite, so that the mechanical property of the brake disc is poor; compared with the prior art, the ceramic particles of the aluminum matrix composite brake disc prepared by the preparation method provided by the invention are more uniformly distributed, and the prepared aluminum matrix composite brake disc has good wear resistance and toughness.
3. In the prior art, in the aluminum matrix composite brake disc prepared by vacuum stirring casting, the adding amount of the ceramic particles is limited, because the adding of the ceramic particles can improve the wear resistance but can reduce the toughness. Therefore, the addition amount of the ceramic particles in the brake disc made of the aluminum matrix composite material prepared by the prior art is about 20 percent, so that the brake disc is ensured to have wear resistance and not too low in toughness. Compared with the prior art, the aluminum matrix composite brake disc prepared by the invention has more uniform internal structure, when the addition of the ceramic particles exceeds 20%, the added ceramic particles exist near the transition layer, and the brake disc as a whole still has good toughness, can improve the wear resistance and has better overall mechanical property.
4. Compared with the defects that the existing vacuum stirring casting method is easy to generate air holes, impurities and the like, the aluminum matrix composite brake disc prepared by the preparation method provided by the invention has more uniform tissue, fewer defects and no defects of air holes, impurities and the like, so that the aluminum matrix composite brake disc has better mechanical properties compared with the aluminum matrix composite brake disc in the prior art.
5. Compared with the prior art, the vacuum stirring casting equipment with high price is not adopted, so that the production cost is greatly reduced.
6. In the prior art, the vacuum stirring casting process needs to be carried out at high temperature, and operators may have operation safety risk during operation, while the stirring friction processing process is carried out at non-high temperature, so that the process is simplified and the safety of process operation is ensured.
7. In the preparation method, the prepared aluminum-based composite board is specially used for preparing the brake disc, compared with the prior art, the size of the reinforced particles is screened, the reinforced particles are normally distributed, and the large particles are beneficial to improving the braking performance of the brake disc; the small particles can improve the wear resistance of the brake disc, thereby improving the overall mechanical property of the brake disc.
8. In the preparation method, the reinforced particles are treated by adopting roasting pretreatment in the process of preparing the aluminum-based composite boardCan form a layer of SiO2The oxide film is used for increasing the wettability between the reinforced particles and the aluminum-based composite material and improving the performance of the composite material, thereby meeting the requirement that the aluminum-based composite layer plate is used for a brake disc.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (19)

1. A preparation method for preparing an aluminum matrix composite brake disc is characterized by comprising the following steps:
an aluminum material melting step S2: completely melting the aluminum material to form aluminum liquid;
melt forming step S3: adding an alloying material into the aluminum liquid to form a melt;
mechanical stirring step S4: a step of mechanically stirring the melt;
reinforcing particle addition step S5: adding the reinforcing particles to the melt, and performing accelerated mechanical stirring;
rolling step S6: rolling the melt into an aluminum-based composite plate under a vacuum condition;
friction stir processing step S7: and (2) carrying out friction stir processing on the surface of the composite structure of the aluminum-based composite plate and the brake disc blank prepared in advance, and combining the aluminum-based composite plate and the brake disc blank together, wherein the surface of the composite structure is the upper surface of the aluminum-based composite plate except for the lower surface of the aluminum-based composite plate, the contact surface of the aluminum-based composite plate and the brake disc blank.
2. The manufacturing method for manufacturing an aluminum matrix composite brake disc according to claim 1, characterized in that it comprises, before the reinforcing particles addition step S5, a reinforcing particles screening step Z1: and (3) screening the enhanced particles.
3. The manufacturing method for manufacturing an aluminum matrix composite brake disc according to claim 2, wherein in the reinforcing particle screening step Z1, the reinforcing particles having a particle size of 10 to 40 μm and a normal distribution value of 10 to 30 μm are screened.
4. The production method for producing an aluminum matrix composite brake disc according to claim 2, wherein the reinforcing particles are SiC particles.
5. The manufacturing method for manufacturing an aluminum matrix composite brake disc according to claim 2, characterized in that between the reinforcing particle adding step S5 and the reinforcing particle screening step Z1, a reinforcing particle roasting pretreatment step Z2 is included: and (3) carrying out roasting pretreatment on the reinforced particles to remove surface impurities and adsorb moisture.
6. The production method for an aluminum matrix composite brake disc according to claim 5, characterized in that in the reinforcing particle firing pretreatment step Z2 including the formation of a layer of SiO on the surface of the SiC particles as the reinforcing particles2And oxidizing the film.
7. The manufacturing method for manufacturing an aluminum matrix composite brake disc according to claim 5, wherein the reinforcing particles are added in step S5 at a speed of 2-5 g/S.
8. The method for manufacturing an aluminum matrix composite brake disc according to claim 2, characterized in that it comprises, before the melt forming step S3, a modifier and refiner weighing step X1: and weighing the alterant and the refiner based on the weight ratio of the aluminum material.
9. The method for manufacturing an aluminum matrix composite brake disc according to claim 8, wherein between the melt forming step S3 and the alterant and refiner weighing step X1, the method comprises a step X3 of adding the alterant and the refiner to the aluminum liquid to form the melt.
10. The method for manufacturing an aluminum matrix composite brake disc as claimed in claim 9, wherein between the step of weighing the alterant and the refiner X1 and the step of adding the alterant and the refiner to the aluminum liquid X3, the method comprises a baking step X2: and baking the alterant and the refiner to remove water.
11. The method for manufacturing an aluminum matrix composite brake disc according to claim 1, comprising an aluminum material preparation step S1 before the aluminum material melting step S2: baking the aluminum material and removing moisture.
12. The manufacturing method for manufacturing an aluminum-based composite brake disc according to claim 1, wherein the friction stir processing step S7 includes a mixing step S71 and a cooling step S72, and in the mixing step S71, the brake disc blank and the aluminum-based composite plate are sufficiently mixed together at the portions where they contact each other; in the cooling step S72, a brake disk having a transition layer is formed.
13. The manufacturing method for manufacturing an aluminum matrix composite brake disc according to claim 1, wherein in the friction stir processing step S7, the friction stir processing has a stirring rotation speed of 600 to 1200 rpm and a feeding speed of 100 to 500 mm/min.
14. The manufacturing method for manufacturing an aluminum matrix composite brake disc according to any one of claims 1 to 8, wherein in the reinforcing particle roasting pretreatment step S3, the temperature of the roasting pretreatment is 400 to 1000 ℃.
15. The manufacturing method for the brake disc made of the aluminum matrix composite according to any one of claims 1 to 8, wherein in the mechanical stirring step S4, the rotation speed of the motor is controlled to be 500-600 rpm.
16. The method for manufacturing a brake disc made of an aluminum-based composite material according to any one of claims 1 to 8, wherein in the friction stir processing step S7, a transition layer is formed between the aluminum-based composite plate and the brake disc blank.
17. The preparation method for preparing the brake disc made of the aluminum-based composite material according to any one of claims 1 to 8, wherein the tensile strength Rm of the aluminum-based composite plate is not less than 140MPa, the elongation A after fracture is not less than 0.5%, and the hardness is not less than 65 HBW.
18. The production method for producing an aluminum matrix composite brake disc according to claim 16, wherein the transition layer has a spherical or spheroidal silicon phase therein.
19. The production method for producing an aluminum matrix composite brake disc according to claim 18, wherein the length of the silicon phase is 10 μm or less, and the sphericity of the silicon phase is 20% to 100%.
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CN202011009039.1A CN112143921B (en) 2020-09-23 2020-09-23 Preparation method for preparing aluminum matrix composite brake disc
PCT/CN2021/119478 WO2022063099A1 (en) 2020-09-23 2021-09-20 Composite material brake rotor, preparation method therefor, and friction stir tool
MX2023003366A MX2023003366A (en) 2020-09-23 2021-09-20 Composite material brake rotor, preparation method therefor, and friction stir tool.
CN202180065279.XA CN116348234A (en) 2020-09-23 2021-09-20 Composite brake disc, preparation method thereof and friction stir tool
US18/028,003 US20230349435A1 (en) 2020-09-23 2021-09-20 Composite brake disc, preparation method thereof and friction stir tool

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CN116348234A (en) * 2020-09-23 2023-06-27 中车戚墅堰机车车辆工艺研究所有限公司 Composite brake disc, preparation method thereof and friction stir tool
CN113560815A (en) * 2021-06-23 2021-10-29 广州三的投资管理企业(有限合伙) Preparation method and application of aluminum-based carbon ceramic brake disc
CN113738774A (en) * 2021-09-10 2021-12-03 中车大同电力机车有限公司 Transmission hollow shaft, bogie coupling and manufacturing method of transmission hollow shaft
CN114561641B (en) * 2022-02-11 2023-11-03 上海壬丰复合材料有限公司 Surface friction treatment method for ceramic reinforced aluminum matrix composite brake disc
CN116690125B (en) * 2023-07-28 2023-10-03 中车戚墅堰机车车辆工艺研究所有限公司 Preparation method of aluminum-based composite brake disc and brake disc

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