CN112707735A - 一种碳陶制动盘的快速制备方法 - Google Patents
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Abstract
本发明公开了一种碳陶制动盘的快速制备方法。首先制备变密度碳纤维预制体,接着将预制体加工出制动盘外形,再对其进行CVI增密,最后熔融渗硅制备出碳陶制动盘。本发明在预制体制备过程中,采用变密度的预制体,同时在预制体阶段先进行加工,可以大幅缩短沉积时间,实现碳陶制动盘的快速制备。另外,预制体下层以网胎层为主,密度较低,通过沉积渗硅形成更加致密的陶瓷基体,作为碳陶制动盘的摩擦面,可以提高刹车盘的耐磨性以及抗氧化性能,而预制体中层以及上层采用更高密度的预制体及针刺密度,对刹车盘的散热及整体增强更为有利。本发明制备的碳陶制动盘密度均匀,生产周期缩短、生产成本大幅下降,对推动碳陶制动盘普及应用有重要的意义。
Description
技术领域
本发明涉及一种碳陶制动盘的快速制备方法,属于碳陶复合材料制备技术领域。
背景技术
碳陶复合材料具有密度低、强度高、耐高温、摩擦系数稳定、磨损量小等优点,被公认为新一代刹车材料。碳陶复合材料制动盘与传统钢制动盘相比,重量降低三分之二,能载水平提高一倍,使用寿命提高1-2倍,在高速列车、赛车、高档轿车、重载车辆以及特种车辆等刹车系统上具有广泛的应用前景。但是,碳陶制动盘制造周期长、材料加工难度大、碳纤维预制体昂贵,致使碳陶制动盘生产制造成本居高不下,严重限制了其应用广市场推。
中国专利CN108644260B公布了一种高速列车用轻量一体化制动轴盘的制备方法,其增密条件为:碳源气体与稀释气体的体积比为0.5~2,炉内压力500~5000Pa,沉积温度900~1100℃,沉积时间300~500h,增密后样件密度1.3~1.6g/cm3,增密工序耗时长,通常需两次或多次沉积才能达到所需密度。同时,考虑到每次增密过程都需要对半成品的表面进行粗加工,以打开半成品表面被沉积碳堵住的孔道,便于提高下一次沉积的效率,这样下来,相应的也会增加机加工的时长。
发明内容
本发明针对现有碳陶制动盘生产工艺过程中CVI增密周期长、加工耗时多、生产成本居高不下等问题,本发明的目的在于提供一种碳陶制动盘的快速制备方法,通过制备变密度预制体结合化学气相沉积以及熔融渗硅,明显缩短了碳陶制动盘CVI增密工序和机加工工序耗时,大幅降低了产品生产成本。
为了实现上述目的,本发明采用如下技术方案
本发明一种碳陶制动盘的快速制备方法,包括如下步骤:
步骤1:变密度预制体的制备
所述预制体采用碳布、无纬布、网胎的不同组合交替叠层并逐层针刺制备,通过控制针刺密度,制成整体结构的变密度预制体,所述变密度预制体包含预制体上层;预制体中层、预制体下层,其中预制体上层,碳布与网胎的层数之比为4~6:1,预制体中层,无纬布与网胎的层数之比为3~4:1;预制体下层,为全网胎;
步骤2变密度预制体的加工
依据碳陶制动盘的设计图纸,将步骤1所制得的变密度预制体进行加工,获得碳纤维预制体;
步骤3:CVI增密
将步骤2所得制动盘预制体进行化学气相沉积获得碳碳预制体,
步骤4:熔融渗硅
将步骤3所得碳碳预制体通过熔融渗硅获得碳陶制动盘。
本发明的制备方法,在预制体制备过程中,采用变密度的预制体,同时在预制体阶段先进行加工,缩短了后期CVI增密过程中气体沉积的扩散路径,可以大幅缩短沉积时间,实现碳陶制动盘的快速制备。在本发明的变密度体的制备过程中,预制体下层,采用全网胎叠层并逐层针刺制备,因而密度较低,后期通过沉积渗硅形成更加致密的陶瓷基体,应用作为碳陶制动盘的摩擦面,可以提高刹车盘的耐磨性以及抗氧化性能,而预制体中层,采用无纬布与网胎叠层并逐层针刺制备,预制体上层,采用碳布与网胎叠层并逐层针刺制备,密度更高,且逐层增高,对刹车盘的散热及整体增强更为有利。
优选的方案,步骤1中,所述变密度预制体中所用碳纤维为T700级。在实际操作过程中,采用东丽T700-12K或同级别其他型号
优选的方案,步骤1中,所述碳布的密度为320~400g/m2。
优选的方案,步骤1中,所述无纬布的密度为240~300g/m2。
优选的方案,步骤1中,所述网胎面密度为60~100g/m2。
优选的方案,步骤1中,所述碳布在层叠过程中的铺设方式如下:方式一,相邻两层碳布中的长碳纤维取向按照0°/90°铺设,方式二、相邻四层碳布中的长碳纤维取向按照-45°/0°/45°/90°铺设。
优选的方案,步骤1中,所述无纬布在层叠过程中的铺设方式如下:方式一,相邻两层无纬布中的长碳纤维取向按照0°/90°铺设,方式二,或相邻四层无纬布中的长碳纤维取向按照-45°/0°/45°/90°铺设。
优选的方案,步骤1中,所述变密度预制体的整体密度为0.4~0.45g/cm3。
优选的方案,步骤1中,预制体上层的厚度为10~15mm,预制体中层的厚度为20~25mm,预制体下层的厚度为10~12mm。
发明人发现,预制体各层采用上述厚度范围,最终材料的性能最佳。
优选的方案,步骤1中,预制体上层的制备过程中,控制针刺的密度25~30针/cm2。
优选的方案,步骤1中,预制体中层的制备过程中,控制针刺的密度25~30针/cm2。
优选的方案,步骤1中,预制体下层的制备过程中,控制针刺的密度15~18针/cm2。
优选的方案,步骤1中,所述预制体上层的密度为0.6~0.65g/cm3,预制体中层的密度为0.5~0.55g/cm3,预制体下层的密度为0.4~0.45g/cm3。发明人发现,将密度各层预制体的密度控制在上述梯度范围内,不仅沉积效率最高,而且最终所制备的碳陶制动盘性能最佳。
优选的方案,步骤3中,化学气相沉积过程中,碳源气体选自丙烯或/和天然气,稀释气体选自Ar或/和N2;碳源气体与稀释气体的流量比1~2:1。
优选的方案,所述化学气相沉积过程中,气体由预制体下层的下方通入。
在本发明中,预制体下层以网胎层为主,密度低孔隙多,气体由预制体下层通入,可以进一步缩短沉积时间。
优选的方案,步骤3中,化学气相沉积过程中,沉积的温度为920~1050℃,沉积的压力为3~5kPa,沉积的时间为80~120h。
在实际操作过程中,化学气相沉积后,需将沉积后的样件除端面尺寸外其余加工至制动盘成品尺寸。
优选的方案,步骤3中,所得碳碳预制体的密度为1.35~1.55g/cm3。
优选的方案,步骤4中,所述熔融渗硅在真空气氛下进行,所述熔融渗硅的温度为1500~1900℃,熔融渗硅的时间为1~3h。
优选的方案,步骤4中,碳陶制动盘的密度为2.0~2.5g/cm3
实际操作过程中,将熔融渗硅后的制动盘进行端面精磨即可得到碳陶制动盘成品。
原理与优势
本发明的制备方法,在预制体制备过程中,采用变密度的预制体,化学气相沉积过程中,气体由预制体下层的下方通入,同时在预制体阶段先进行加工,缩短了后期CVI增密过程中气体沉积的扩散路径,可以大幅缩短沉积时间,沉积时间相对于现有技术缩短50~70h。实现碳陶制动盘的快速制备。另外,在本发明中,预制体下层中,以网胎层为主,密度较低,后期通过沉积渗硅形成更加致密的陶瓷基体,应用作为碳陶制动盘的摩擦面,可以提高刹车盘的耐磨性以及抗氧化性能,而预制体中层以及上层采用更高密度的预制体及针刺密度,对刹车盘的散热及整体增强更为有利。
本发明制备的碳陶制动盘产品密度均匀,碳陶制动盘生产周期明显缩短、生产成本大幅下降,对推动碳陶制动盘普及应用有重要的意义。
附图说明
图1为碳陶制动盘生产流程示意图,
图2为变密度预制体结构示意图,
图3为变密度预制体加工后实物图。
以下结合附图和具体实施方式对本发明做进一步说明。
具体实施方式
以下结合附图对本发明做进一步的详细说明。
本发明一种碳陶制动盘的快速制备方法,其具体制备步骤如下:
在以下实施例中,所用碳布的面密度为350g/m2,所述无纬布的密度为280g/m2,所述网胎面密度为80g/m2。
实施例1
步骤1:变密度预制体的制备
变密度预制体由预制体上层;预制体中层、预制体下层,其中预制体上层由碳布与网胎交替叠层并逐层针刺制备,碳布:网胎=4:1,针刺密度为25针/cm2,厚度为10mm,其中碳布的长碳纤维铺设方式为:0°/90°
预制体中层由无纬布与与网胎交替叠层并逐层针刺制备,无纬布:网胎=3:1,针刺密度为25针/cm2,厚度为25mm,其中碳布的长碳纤维铺设方式为:-45°/0°/45°/90°
预制体下层由全网胎层叠并逐层针刺制备,针刺密度为15g/cm2;厚度为10mm,最终获得整体结构碳纤维预制体,预制体密度0.45g/cm3。
步骤2:预制体加工
依据制动盘图纸,将变密度预制体加工出外径420mm,内径200mm,总厚度为45mm的圆环,然后在下层结构单元内加工出制动盘加强筋等结构,加工后预制体如图2所示。
步骤3:CVI增密及加工
将加工后的预制体置于化学气相沉积炉中,通入丙烯和氩气混合气体(丙烯:氩气=1:1),气体通入方式为:从预制体下层的底部通入,沉积温度为920℃,沉积压力为3~5kPa,沉积时间为80h,沉积后样品密度1.37g/cm3;将沉积后的样件除端面尺寸外其余加工至制动盘成品尺寸。
步骤4:熔融渗硅
将加工后的制动盘样件放入盛有硅粉的坩埚中,然后置于高温炉中进行熔融渗硅,熔融渗硅温度1900℃,真空气氛,处理时间1h,熔融渗硅后产品密度2.15g/cm3。
步骤五:端面精磨
将熔融渗硅后的制动盘进行端面精磨即可得到碳陶制动盘成品。
对比例1:
一种碳陶制动盘的快速制备方法,其具体制备步骤如实施例1所述,所不同的是,对比例1中的碳纤维预制体直接采用无纬布与网胎层交替叠层并逐层针刺的方式进行,其中长碳纤维的铺设方式采用:-45°/0°/45°/90°,所获得的碳纤维预制体的密度为0.45g/cm3,厚度为45mm,其它的工艺制备条件与实施例1一致。
实施例2:
步骤1:变密度预制体的制备
变密度预制体由预制体上层;预制体中层、预制体下层,其中预制体上层由碳布与网胎交替叠层并逐层针刺制备,碳布:网胎=6:1,针刺密度为30针/cm2,厚度为15mm,其中碳布的铺设方式为:-45°/0°/45°/90°
预制体中层由无纬布与与网胎交替叠层并逐层针刺制备,无纬布:网胎=4:1,针刺密度为30针/cm2,厚度为20mm,其中碳布的铺设方式为:-45°/0°/45°/90°
预制体下层由全网胎层叠并逐层针刺制备,针刺密度为18针/cm2;厚度为10mm,最终获得整体结构碳纤维预制体,预制体密度0.50g/cm3。
步骤2:预制体加工
依据制动盘图纸,将变密度预制体加工出外径400mm,内径180mm,总厚度为45mm的圆环,然后在上下层结构单元内加工出制动盘加强筋等结构。
步骤3:CVI增密及加工
将加工后的预制体置于化学气相沉积炉中,通入天然气和N2气混合气体(天然气:N2=1.5:1),沉积温度为950℃,沉积压力为3~5kPa,沉积时间为120h,沉积后样品密度1.50g/cm3;将沉积后的样件除端面尺寸外其余加工至制动盘成品尺寸。
步骤4:熔融渗硅
将加工后的制动盘样件放入盛有硅粉的坩埚中,然后置于高温炉中进行熔融渗硅,熔融渗硅温度1500℃,真空气氛,处理时间3h,熔融渗硅后产品密度2.50g/cm3。。
步骤5:端面精磨
将熔融渗硅后的制动盘进行端面精磨得到碳陶制动盘成品。
实施例3:
步骤1:变密度预制体的制备
变密度预制体由预制体上层;预制体中层、预制体下层,其中预制体上层由碳布与网胎交替叠层并逐层针刺制备,碳布:网胎=5:1,针刺密度为27针/cm2,厚度为13mm,其中碳布的铺设方式为:-45°/0°/45°/90°
预制体中层由无纬布与与网胎交替叠层并逐层针刺制备,无纬布:网胎=3.5:1,针刺密度为27针/cm2,厚度为20mm,其中碳布的铺设方式为:0°/90°
预制体下层由全网胎层叠并逐层针刺制备,针刺密度为17针/cm2;厚度为12mm,最终获得整体结构碳纤维预制体,预制体密度0.47g/cm3。
步骤2:预制体加工
依据制动盘图纸,将变密度预制体加工出外径400mm,内径180mm,总厚度为45mm的圆环,然后在上下层结构单元内加工出制动盘加强筋等结构。
步骤3:CVI增密及加工
将加工后的预制体置于化学气相沉积炉中,通入天然气、丙烯和氩气混合气体(天然气与丙烯的混合气:氩气=1.2:1),沉积温度为1020℃,沉积压力为3~5kPa,沉积时间为100h,沉积后样品密度1.44g/cm3;将沉积后的样件除端面尺寸外其余加工至制动盘成品尺寸。
步骤4:熔融渗硅
将加工后的制动盘样件放入盛有硅粉的坩埚中,然后置于高温炉中进行熔融渗硅,熔融渗硅温度1700℃,真空气氛,处理时间1.5h,熔融渗硅后产品密度2.42g/cm3。。
步骤5:端面精磨
将熔融渗硅后的制动盘进行端面精磨得到碳陶制动盘成品。
对以上所有的实施例及对比例进行性能测试,测试包括:CVI工艺完成后的半成品进行密度测试;碳陶制动盘的动摩擦系数;熔融渗硅完成后获得的碳陶制动盘中,全网胎层部分的开孔率(对于对比例1,由于省掉了全网胎层部分,所以表1中的开孔率表示的是整体的开孔率),最终所获得的测试数据如表1所示:
表1
实施例1 | 对比例1 | 实施例2 | 实施例3 | |
CVI后的密度(g/cm<sup>3</sup>) | 1.38 | 1.02 | 1.50 | 1.44 |
动摩擦系数(全网胎层面) | 0.43 | 0.23 | 0.50 | 0.46 |
开孔率(全网胎部分) | 1.0% | 12.3% | 0.5% | 0.7% |
通过表1可以发现,在相同的CVI沉积时间下,实施例1所达到的密度明显高于对比例1中的,也即:对于采用“变密度”方式设计的碳纤维预制体可在更短的CVI沉积时间达到所需要的熔融渗硅前的密度,大大的缩短了碳陶制动盘的生产时间,降低了生产成本;从表1中的开孔率的大小可以发现,采用“变密度”方式设计的碳纤维预制体制备的碳陶材料,其开孔率要远低于普通的碳纤维预制体制备的碳陶材料,因此,可以肯定的是“变密度”碳纤维预制体制备的碳陶材料,其全网胎层表面的致密性要高于“普通的碳纤维预制体”,而致密性越高,其耐磨性更好,因此,所表现出的抗磨损能力更佳。另外,从动摩擦系数的测试结果来看,采用“变密度”碳纤维预制体制备的碳陶材料所表现出动摩擦系数值相比于普通的碳陶材料的动摩擦系数值要高,主要原因也是由于“变密度”碳纤维预制体制备的碳陶材料的“全网胎层”表面的致密度要更高,其所形成的SiC含量相对更高,而SiC作为一种增摩的硬质相,可以在一定程度上提高动摩擦系数。因此,本发明提出的一种碳陶制动盘的快速制备方法在降低生产成本,提供产品加工效率的同时,可以显著的改善现有普通碳陶材料的摩擦磨损性能。
Claims (10)
1.一种碳陶制动盘的快速制备方法,其特征在于:包括如下步骤:
步骤1:变密度预制体的制备
所述预制体采用碳布、无纬布、网胎的不同组合交替叠层并逐层针刺制备,通过控制针刺密度,制成整体结构的变密度预制体,所述变密度预制体包含预制体上层;预制体中层、预制体下层,其中预制体上层,碳布与网胎的层数之比为4~6:1,预制体中层.,无纬布与网胎的层数之比为3~4:1;预制体下层,为全网胎;
步骤2变密度预制体的加工
依据碳陶制动盘的设计图纸,将步骤1所制得的变密度预制体进行加工,获得碳纤维预制体;
步骤3:CVI增密
将步骤2所得制动盘预制体进行化学气相沉积获得碳碳预制体,
步骤4:熔融渗硅
将步骤3所得碳碳预制体通过熔融渗硅获得碳陶制动盘。
2.根据权利要求1所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤1中,所述碳布的密度为320~400g/m2;所述无纬布的密度为240~300g/m2,所述网胎面密度为60~100g/m2。
3.根据权利要求1所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤1中,所述碳布在层叠过程中的铺设方式如下:方式一,相邻两层碳布中的长碳纤维取向按照0°/90°铺设,方式二、相邻四层碳布中的长碳纤维取向按照-45°/0°/45°/90°铺设;
步骤1中,所述无纬布在层叠过程中的铺设方式如下:方式一,相邻两层无纬布中的长碳纤维取向按照0°/90°铺设,方式二,或相邻四层无纬布中的长碳纤维取向按照-45°/0°/45°/90°铺设。
4.根据权利要求1所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤1中,所述变密度预制体的整体密度为0.4~0.45g/cm3。
5.根据权利要求1所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤1中,预制体上层的厚度为10~15mm,预制体中层的厚度为20~25mm,预制体下层的厚度为10~12mm。
6.根据权利要求1所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤1中,预制体上层的制备过程中,控制针刺的密度25~30针/cm2;预制体中层的制备过程中,控制针刺的密度25~30针/cm2;预制体下层的制备过程中,控制针刺的密度15~18针/cm2。
7.根据权利要求1所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤1中,所述预制体上层的密度为0.6~0.65g/cm3,预制体中层的密度为0.5~0.55g/cm3,预制体下层的密度为0.4~0.45g/cm3。
8.根据权利要求1所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤3中,化学气相沉积过程中,碳源气体选自丙烯或/和天然气,稀释气体选自Ar或/和N2;碳源气体与稀释气体的流量比1~2:1;
所述化学气相沉积过程中,气体由预制体下层的下方通入。
9.根据权利要求1或8所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤3中,化学气相沉积过程中,沉积的温度为920~1050℃,沉积的压力为3~5kPa,沉积的时间为80~120h;
步骤3中,所得碳碳预制体的密度为1.35~1.55g/cm3。
10.根据权利要求1所述的一种碳陶制动盘的快速制备方法,其特征在于:
步骤4中,所述熔融渗硅在真空气氛下进行,所述熔融渗硅的温度为1500~1900℃,熔融渗硅的时间为1~3h;
步骤4中,碳陶制动盘的密度为2.0~2.5g/cm3。
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