CN113444915A - 一种低成本铜基粉末冶金摩擦材料及其制备方法 - Google Patents
一种低成本铜基粉末冶金摩擦材料及其制备方法 Download PDFInfo
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 49
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 41
- 239000010949 copper Substances 0.000 title claims abstract description 41
- 239000002783 friction material Substances 0.000 title claims abstract description 35
- 238000004663 powder metallurgy Methods 0.000 title claims abstract description 27
- 238000002360 preparation method Methods 0.000 title claims abstract description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 22
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 18
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 18
- 239000010439 graphite Substances 0.000 claims abstract description 18
- 238000005245 sintering Methods 0.000 claims abstract description 18
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims abstract description 15
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims abstract description 12
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 12
- 238000002156 mixing Methods 0.000 claims abstract description 9
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- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 claims description 2
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 238000000748 compression moulding Methods 0.000 claims description 2
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- 239000012798 spherical particle Substances 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N sulfuric acid Substances OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 2
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- 229910052751 metal Inorganic materials 0.000 description 8
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- 239000000314 lubricant Substances 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- 239000000203 mixture Substances 0.000 description 5
- 229910052725 zinc Inorganic materials 0.000 description 5
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- 230000001050 lubricating effect Effects 0.000 description 4
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- 229910052718 tin Inorganic materials 0.000 description 4
- 229910052750 molybdenum Inorganic materials 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 3
- 238000005728 strengthening Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 2
- 235000015895 biscuits Nutrition 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
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- 229910052748 manganese Inorganic materials 0.000 description 2
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- 238000002844 melting Methods 0.000 description 2
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- 229910052961 molybdenite Inorganic materials 0.000 description 2
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- 229910052719 titanium Inorganic materials 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052721 tungsten Inorganic materials 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 229910017755 Cu-Sn Inorganic materials 0.000 description 1
- 229910017767 Cu—Al Inorganic materials 0.000 description 1
- 229910017927 Cu—Sn Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- MBMLMWLHJBBADN-UHFFFAOYSA-N Ferrous sulfide Chemical compound [Fe]=S MBMLMWLHJBBADN-UHFFFAOYSA-N 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 238000005411 Van der Waals force Methods 0.000 description 1
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- 150000001875 compounds Chemical class 0.000 description 1
- IYRDVAUFQZOLSB-UHFFFAOYSA-N copper iron Chemical compound [Fe].[Cu] IYRDVAUFQZOLSB-UHFFFAOYSA-N 0.000 description 1
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 1
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- 239000006104 solid solution Substances 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
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- C22C9/00—Alloys based on copper
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/14—Both compacting and sintering simultaneously
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Abstract
一种低成本铜基粉末冶金摩擦材料及其制备方法，属于金属复合材料技术领域，可解决现有铜基粉末冶金摩擦材料成本高及制造工艺难度大的问题，包括如下质量百分比的组分：55%~70%的铜粉，10%~15%的铁粉，4%~8%的锡粉，2%~4%的锌粉，4%~8%的鳞片石墨，10%~14%的硅酸锆。通过球磨混料，压制成型，真空热压烧结，得到具有高摩擦系数、抗磨损能力强和导热性良好的粉末冶金摩擦材料，本发明原材料种类少、制备工艺简单，能够在保证铜基摩擦材料润滑性、耐磨性及使用寿命的前提条件下有效降低其生产成本，适用于高速列车制动闸片、汽车刹车片或者风电机组偏航制动片。
Description
技术领域
本发明属于金属复合材料技术领域，具体涉及一种交通运输和机械装备用低成本铜基粉末冶金摩擦材料及其制备方法。
背景技术
铜基粉末冶金摩擦材料具有良好的耐磨性、导热性及摩擦系数高且稳定等特点，在航空、汽车、船舶、工程机械和风电机组偏航系统等刹车装置及离合器方面得到了广泛的应用。然而，随着机械装备的动力、速度和负载在不断增大，对摩擦片材料的要求越来越高。传统的铜基粉末冶金材料在使用过程中存在磨损较严重、耐热性不足和寿命低等缺点，已经难以满足新型传动装置制动性能的要求，急需开发具有寿命长、适应的摩擦系数、耐磨损且制动噪声小的铜基摩擦片材料，这对提升我国高端机械装备的使役性能具有重要的意义。
另一方面，目前的铜基粉末冶金摩擦材料通常由金属基体、增摩剂和润滑组元等三类组分构成，是一种含有多种金属和非金属组元的复合材料。在摩擦片制造过程中，大多需要在Cu-Sn、Cu-Al和Cu-Pb等铜合金基体中加入Zr、Zn、Fe、Ni、Mo、W、Cr、Ti、Mn等强化元素形成固溶体或者金属颗粒呈游离态均匀分布于基体中，提高金属基体的强度、减小磨损。同时，为了有效地阻止粘着、稳定摩擦，通常还需要添加质量分数为2%～12%的MoS2与石墨搭配形成双固体润滑剂效应。金属强化元素和MoS2润滑剂的加入虽然能够改善复合材料的耐磨性和摩擦系数，提高部件的使用寿命，但是复杂的成分构成不仅增加了原料成本，而且协调各组元之间的性能匹配也加大了制造工艺的难度。因此，如何简化组元构成和优化制备工艺，研制出适合多种工况条件的低成本铜基粉末冶金摩擦材料，成为了提高铜基粉末冶金摩擦材料经济适用性亟待解决的问题。
发明内容
本发明针对现有铜基粉末冶金摩擦材料成本高及制造工艺难度大的问题，提供一种具有高摩擦系数、耐磨损以及抗热衰退能力强等特点的铜基粉末冶金摩擦材料，通过对铜基摩擦材料配方的调整和制备工艺的优化，能够在保证铜基摩擦材料多环境适用性的前提条件下有效降低生产成本。
本发明采用如下技术方案：
一种低成本铜基粉末冶金摩擦材料，包括如下质量百分比的组分：55%~70%的铜粉，10%~15%的铁粉，4%~8%的锡粉，2%~4%的锌粉，4%~8%的鳞片石墨，10%~14%的硅酸锆。
进一步地，所述铜粉为雾化或者电解球形粉，纯度大于99.9%，粒径为75~150 μm；铁粉为雾化或者电解球形粉，纯度大于99.9%，粒径为45~50μm；锡粉为雾化球形粉，纯度大于99.9%，粒径为70~80μm；锌粉为雾化球形粉，纯度大于99.9%，粒径为45~50μm；鳞片石墨的粒度为250~300μm，混料前先浸入浓硫酸或浓硝酸中，在80~100 ℃下进行表面氧化处理15min；硅酸锆为球形颗粒、纯度为99%、粒度为120~150μm。
一种低成本铜基粉末冶金摩擦材料的制备方法，包括如下步骤：
第一步，配料：按质量百分比分别称取铜粉、铁粉、锡粉、锌粉、鳞片石墨和硅酸锆粉；
第二步，混料：将第一步配好的原料在行星式球磨机中混合均匀；
第三步，成型：根据所需试件规格将第二步混合均匀的粉末在钢制模具中300~400MPa压制成胚体；
第四步，真空热压烧结：将第三步压制成型的原料置于热压烧结炉中，以5~10 ℃/min的速率升温至800~850 ℃，保持真空度0.1~1 Pa，在压力15~30 MPa烧结30 min，然后随炉冷却至室温。
本发明的原理如下：
铜基体采用锡和锌元素合金化，锡、锌能溶入铜晶格并形成复杂化合物以强化基体，改善铜基体物理力学性能、热稳定性及摩擦特性，同时低熔点的锡和锌在烧结升温过程中熔化，使烧结过程为液相烧结，能够降低烧结温度和促进烧结的致密化过程。采用铁颗粒和硅酸锆作为摩擦组元提供稳定的摩擦系数。材料基体中均匀弥散分布的铁颗粒不仅起到颗粒强化作用，提高材料的强度和硬度，还能够凭借其自身的强度和硬度，在摩擦过程中直接与对偶表面相接触，承受摩擦阻力而提高材料的摩擦系数，起到有效增磨的作用；硅酸锆具有很高的熔点、硬度和化学稳定性，不会与摩擦材料中的其他成分发生任何化学反应，但却能被基体金属铜和增强组元铁润湿，它的添加可以显著提高材料的抗热震和高温摩擦性能。采用鳞片石墨作为润滑组元，在摩擦过程中，石墨晶体的层与层之间由于范德华力结合较弱而很容易相互滑动，从而减小了摩擦，降低材料磨损率，保护对偶被磨损。混料前，需要对鳞片石墨进行预氧化处理，去除无定型碳的同时提高其表面化学活性，改善石墨与金属基体的界面润湿。
本发明与现有技术相比，具有如下优点：
1. 本发明通过铜、锡、锌和铁金属组元进行优化组合，获得一种具有物理力学性能、热稳定性及摩擦特性的金属基体，合金元素种类少、配方简单，避免了镍、钼、钨、铬、钛、锰等稀有金属的使用，能够降低铜基粉末冶金摩擦材料的制造成本。
2. 本发明采用单一润滑组元方案，以鳞片石墨作为固体润滑剂，避免了双固体润滑方案中添加MoS2作为固体润滑剂时存在的缺陷：一方面，高温烧结过程中MoS2在铜-铁合金基体中不能稳定存在，MoS2 会与铁组分在烧结过程中发生反应而失去其层片状结构，反应会生成硫化亚铁、钼单质等新相。因此，添加MoS2作固体润滑剂在铜/铁基摩擦材料中所起的润滑作用会被削弱。另一方面，MoS2粉末的价格高昂（约19万元/吨），在铜基粉末冶金摩擦材料中大量添加MoS2固体润滑剂将大幅度提高产品的生产成本。
3. 本发明的铜基摩擦材料具有良好的综合力学性能和稳定的摩擦磨损性能，硬度达到28～30 HB，平均静态摩擦系数达0.38～0.42，磨损量低于2.5×10-4 mm3·m-1·N-1，能够充分满足汽车、高速列车以及风电发动机主轴制动的要求。
附图说明
图1为本发明实施例2和实施例3制备的铜基粉末冶金摩擦材料显微组织的金相照片，其中，a为实施例2，b为实施例3。
图2为本发明实施例2制备的铜基粉末冶金摩擦材料显微组织的FESEM照片和EDX元素分布图。
图3为本发明制备的铜基粉末冶金摩擦材料的硬度。
图4为本发明制备的铜基粉末冶金摩擦材料在不同载荷下的摩擦系数和磨损率，其中，a为摩擦系数，b为磨损率。
具体实施方式
一种低成本铜基粉末冶金摩擦材料，包括以下质量百分比的组分：55%~70%的铜粉，10%~15%的铁粉，4%~8%的锡粉，2%~4%的锌粉，4%~8%的鳞片石墨，10%~14%的硅酸锆。
将上述配比粉料首先经过球磨机混合均匀，将所得混合粉末在300~400 MPa压力下压制得到素坯；将素坯在800~850 ℃、升温速率5~10 ℃/min，真空度0.1~1Pa，压力15~30MPa下通过真空热压烧结工艺烧结30 min，随炉冷却至室温，即得到所需的铜基摩擦材料样件。通过调节材料成分配比和热压烧结工艺，可以获得结构致密，增强组元和润滑组元分布均匀的铜基粉末冶金摩擦材料。具体实施例见表1所列组成。
采用上述步骤制备得到的铜基粉末冶金摩擦材料经过测量力学性能和摩擦性能，所得到的数据见表2。材料的硬度达到28~30 HB，平均静态摩擦系数达0.38~0.42，磨损量低于2.5×10-4 mm3·m-1·N-1。可以看出，本发明能够在简化组元材料种类的条件下，通过优化组元构成和制备工艺参数，实现铜基摩擦材料优良润滑性、耐磨性及使用寿命。
表1：本发明中各实施例的铜基摩擦材料成分配比和烧结工艺条件
表2：本发明中各实施例铜基摩擦材料的力学性能和摩擦特性（载荷60 N）
本发明可用其他的不违背本发明的精神或主要特征的具体形式来概述。因此，无论从哪一点来看，本发明的上述实施方案都只能认为是对本发明的说明而不能限制发明，权利要求书指出了本发明的范围，而上述的说明并未指出本发明的范围，因此，在与本发明的权利要求书相当的含义和范围内的任何变化，都应认为是包括在权利要求书的范围内。
Claims (3)
1.一种低成本铜基粉末冶金摩擦材料，其特征在于：包括如下质量百分比的组分：55%~70%的铜粉，10%~15%的铁粉，4%~8%的锡粉，2%~4%的锌粉，4%~8%的鳞片石墨，10%~14%的硅酸锆。
2.根据权利要求1所述的一种低成本铜基粉末冶金摩擦材料，其特征在于：所述铜粉为雾化或者电解球形粉，纯度大于99.9%，粒径为75~150 μm；铁粉为雾化或者电解球形粉，纯度大于99.9%，粒径为45~50μm；锡粉为雾化球形粉，纯度大于99.9%，粒径为70~80μm；锌粉为雾化球形粉，纯度大于99.9%，粒径为45~50μm；鳞片石墨的粒度为250~300μm，混料前先浸入浓硫酸或浓硝酸中，在80~100 ℃下进行表面氧化处理15 min；硅酸锆为球形颗粒、纯度为99%、粒度为120~150μm。
3.一种低成本铜基粉末冶金摩擦材料的制备方法，其特征在于：包括如下步骤：
第一步，配料：按质量百分比分别称取铜粉、铁粉、锡粉、锌粉、鳞片石墨和硅酸锆粉；
第二步，混料：将第一步配好的原料在行星式球磨机中混合均匀；
第三步，成型：根据所需试件规格将第二步混合均匀的粉末在钢制模具中300~400 MPa压制成胚体；
第四步，真空热压烧结：将第三步压制成型的原料置于热压烧结炉中，以5~10 ℃/min的速率升温至800~850 ℃，保持真空度0.1~1 Pa，在压力15~30 MPa烧结30 min，然后随炉冷却至室温。
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| CN115896531A (zh) * | 2022-11-14 | 2023-04-04 | 湖南博云新材料股份有限公司 | 一种铜基粉末冶金摩擦材料及其制备方法和应用 |
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| CN114908271A (zh) * | 2022-05-27 | 2022-08-16 | 中国科学院兰州化学物理研究所 | 一种耐高温铜合金基固体润滑复合材料及其制备方法 |
| CN115896531A (zh) * | 2022-11-14 | 2023-04-04 | 湖南博云新材料股份有限公司 | 一种铜基粉末冶金摩擦材料及其制备方法和应用 |
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