CN113880599A - Integrally-formed carbon-ceramic coated disc and preparation method thereof - Google Patents
Integrally-formed carbon-ceramic coated disc and preparation method thereof Download PDFInfo
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Abstract
The invention discloses an integrally formed carbon-ceramic coating disc and a preparation method thereof, wherein a prefabricated body of the integrally formed carbon-ceramic coating disc comprises a supporting prefabricated body and a wear-resistant coating prefabricated body, and the wear-resistant coating prefabricated body and the supporting prefabricated body form a whole through a bonding and/or weaving process; the density of the wear-resistant coating preform is less than that of the support preform; the wear-resistant coating prefabricated body is made of a carbonaceous material; the prefabricated body of the carbon-ceramic coated disc is carbonized and then ceramized to obtain a product, and the wear-resistant coating prefabricated body is converted into a wear-resistant ceramic coating after the carbonization and ceramization; converting the support preform into a carbon-ceramic composite material structure support layer; the ceramic content in the wear-resistant coating is more than 1.2 times of the ceramic content in the carbon-ceramic composite material supporting layer; the carbon ceramic composite material supporting layer and the wear-resistant coating form the carbon ceramic coating disc. The invention has reasonable structural design, simple and controllable preparation process, excellent performance of the obtained product and convenient large-scale industrial application.
Description
Technical Field
The invention belongs to the technical field of rail transit brake discs, and particularly relates to an integrally formed carbon-ceramic coated disc and a preparation method thereof.
Background
At present, carbon-ceramic brake discs are used in the field of rail transit such as automobiles, subways and high-speed rails as a novel product, along with the replacement of the technology, carbon-ceramic coated discs with stronger wear resistance and oxidation resistance are developed and applied in the field of automobile braking such as high-end automobiles, racing automobiles and modified automobiles, but the carbon-ceramic coated discs at the present stage mostly adopt a slurry method (forming interface layer combination), a mould pressing method (combining through an adhesive layer) and the like, but the quality problems of block falling and peeling and the like are often caused by the problems of difference between thermal expansion coefficients of a coating and a substrate and poor bonding technical performance of a joint part in the braking process of the coated discs, and particularly under the slightly severe working condition, the quality problems can occur at a very high probability after sand stones impact the surfaces of the coated discs; the abrasion of the disc is aggravated in a light condition, the brake system is damaged by impact due to continuous block falling and peeling in a moderate condition, so that economic loss is caused, and safety accidents are caused by the fact that the disc, the disc and the caliper are broken in a severe condition.
As various problems in the current stage of the carbon-ceramic coating disk have great restrictions on the application of the carbon-ceramic coating disk, the further development and breakthrough of the industry are seriously influenced; however, the carbon ceramic coated disc has obvious advantages, such as better appearance, high hardness and high wear resistance, the service life of the brake disc is doubled or even multiplied under normal use, the friction surface does not have the non-woven cloth of the traditional carbon ceramic disc, the brake disc is changed into a coating with high ceramic content, and the coating has excellent oxidation resistance and lower friction coefficient heat fading.
Therefore, the inferior and the advantage of the carbon ceramic coating disk are integrated, the improvement of the interlayer shear strength of the joint of the carbon ceramic coating disk and the substrate is very important, and the industry competitiveness and the market acceptance of the product can be further improved.
Disclosure of Invention
Aiming at the technical problems of coating bonding strength and the like of the existing carbon-ceramic coated disc, the invention aims to provide an integrally-formed carbon-ceramic coated disc and a preparation method thereof, wherein a coating disc prefabricated body matrix is prepared by utilizing a bonding weaving or weaving process (a needling mode, puncturing and the like), and the interlaminar shear strength and the performance consistency of the joint of a wear-resistant coating and a carbon-ceramic composite material supporting layer are greatly improved after densification and ceramic treatment; meanwhile, a certain amount of ultra-thin mesh fabric in the wear-resistant coating improves the comprehensive mechanical property of the wear-resistant coating, so that the wear-resistant coating is not easy to collapse, fall off and peel; the method is simple to operate, production operation flows are hardly increased on the basis of the traditional carbon ceramic disc production (2-4 processes are basically required for the carbon ceramic coating disc production at the current stage), the production efficiency is greatly improved, the production cost is saved, and the product quality is improved.
The application field of the integrally formed carbon-ceramic coated disc is wider, for example, in the field of braking of subways and high-speed railways, the environmental adaptability of the carbon-ceramic coated disc is greatly improved, the coating cannot fall off under other severe working conditions such as sand impact, and the like, and meanwhile, the oxidation resistance and the coefficient thermal attenuation resistance of the coating can effectively guarantee the braking performance of the high-speed railways at high speed.
The invention relates to an integrally formed carbon-ceramic coating disc, which comprises a support prefabricated body and a wear-resistant coating prefabricated body, wherein the friction coating prefabricated body and the support prefabricated body form a whole through a bonding and/or weaving process; the density of the wear-resistant coating preform is less than that of the support preform; the wear-resistant coating preform is made of a carbonaceous material, and the coating preform is reinforced by short fibers; the matrix is carburized and then ceramized to obtain a product, and the wear-resistant coating preform is converted into a wear-resistant ceramic coating after carburization and ceramization; converting the support preform into a carbon-ceramic composite material structure support layer; the ceramic content in the wear-resistant coating is more than 1.2 times of the ceramic content in the carbon-ceramic composite material supporting layer; the carbon ceramic composite material supporting layer and the wear-resistant coating form the carbon ceramic coating disc.
The invention relates to an integrally formed carbon-ceramic coated disc, which is characterized in that a support prefabricated body is prepared firstly, then a wear-resistant coating prefabricated body is prepared at a prefabricated body stage through a bonding and/or weaving process to obtain a coated disc prefabricated body matrix, namely, the wear-resistant coating prefabricated body is prepared on at least one surface of the support prefabricated body, and the weaving process is selected from at least one of needling and piercing;
when the wear-resistant coating preform is prepared on 2 surfaces of the supporting preform, the preparation method comprises the following steps:
the ultra-thin mesh fabric is used as a raw material, and the ultra-thin mesh fabric is bonded to the supporting prefabricated body by adopting low-carbon-residue resin; and/or
Connecting the ultrathin mesh fabric to a supporting prefabricated body by using the ultrathin mesh fabric as a raw material and adopting a puncturing process and/or a needling process;
the puncture density of the puncture process is controlled to be 20 +/-10 needles/cm2Preferably 20. + -.5 needles/cm2(ii) a The needling density of the needling process is controlled to be 20 +/-10 needles/cm2Preferably 20. + -.5 needles/cm2The needling depth is 15 +/-10 mm, preferably 15 +/-5 mm, after 2-3 layers of needling, the other surface is replaced, and the abrasion-resistant coating prefabricated body is continuously needled, and the repeated alternation is carried out until the abrasion-resistant coating prefabricated body reaches the set thickness; avoid the large density difference of the coating preform stage caused by the continuous compression of the single side.
The raw material comprises 12K-PANCF ultra-thin mesh fabric; the low carbon residue type resin is selected from one of epoxy resin and phenolic resin;
avoid the large density difference of the coating preform stage caused by the continuous compression of the single side.
The integrally formed carbon-ceramic coated disc has the density of a supporting prefabricated body of 0.45 +/-0.20 g/cm3Preferably 0.55. + -. 0.10g/cm3The density of the wear-resistant coating preform is 0.18 +/-0.10 g/cm3Preferably 0.18. + -. 0.05g/cm3。
According to the integrally formed carbon ceramic coating disc, the thickness of a wear-resistant coating prefabricated body on one side of a supporting prefabricated body is larger than 1mm along the axial direction of the integrally formed carbon ceramic coating disc; preferably 2 to 10mm, more preferably 5 to 7 mm.
The invention relates to an integrally formed carbon-ceramic coated disc, which is characterized in that: the density of the integrally formed carbon ceramic coating disc is 2.00-2.50g/cm3、2.30-2.50g/cm3The aperture ratio is 1 to 10 percent, preferably 1 to 3 percent;
carbon-ceramic compositeThe density of the material supporting layer is 2.00-2.50g/cm3Preferably 2.20-2.50g/cm3The aperture ratio is 1-10%, preferably 1-3%, and the ceramic content is 50-60 wt%, preferably 55 wt%;
the density of the wear-resistant coating is 2.10-2.60g/cm3Preferably 2.30-2.60g/cm3The aperture ratio is 1-8%, the ceramic content is 60-80 wt%, preferably 70 wt%, and the ceramic content of the wear-resistant coating is greater than that of the carbon-ceramic composite material structure support layer.
The shear strength between the wear-resistant coating and the carbon-ceramic composite material supporting layer is greater than 20 MPa.
The invention relates to a preparation method of an integrally formed carbon ceramic coating disc, which comprises the following steps:
(1) at a density of 0.45 + -0.20 g/cm3Preferably 0.55. + -. 0.10g/cm3The supporting prefabricated body is needled with an ultrathin mesh fabric with a certain thickness on two sides to form an ultrathin mesh fabric with the density of 0.18 +/-0.10 g/cm3Preferably 0.18. + -. 0.05g/cm3Preparing a coating disc prefabricated body matrix from the ultrathin mesh fabric coating prefabricated body;
(2) under inert atmosphere, the coating disc prefabricated body substrate is subjected to heat treatment at 1700-2200 ℃, preferably 1800-2000 ℃;
(3) densifying a coated disc preform substrate to 1.20 + -0.10 g/cm by performing a chemical vapor deposition process twice or more3First vapor deposition densifying the coated disc preform substrate to 0.90 + -0.10 g/cm3Preferably 0.95. + -. 0.10g/cm3During the second chemical vapor deposition, the disc surface direction is firstly turned, and then densification is carried out; except for the first vapor deposition, the disc surface direction needs to be adjusted in each subsequent vapor deposition until the set density is reached, and a C/C substrate of the coating disc is obtained; the deposition of the second turnplate surface is a critical step, otherwise serious density deviation quality problems can occur;
(4) siliconizing at a high temperature of 1750 +/-100 ℃, preferably 1700 +/-50 ℃, and infiltrating liquid silicon or silicon vapor into pores of a C/C matrix of the coating disc to perform silicon-carbon reaction to prepare the integrally formed carbon-ceramic coating disc with high interlaminar shear strength and high wear resistance.
The invention relates toThe preparation method of the integrally formed carbon ceramic coating disc comprises the step (1), wherein the needling density of the ultra-thin mesh fabric coating prefabricated body is 20 +/-10 needles/cm2Preferably 20. + -.5 needles/cm2The needling depth is 15 +/-10 mm, preferably 15 +/-5 mm, the needle is rotated by 90 degrees after 1 layer is needled, the needle is replaced to the other surface after 2-3 layers are needled, and needling is continued, so that repeated alternation is realized, and the uniformity of needling indentation and coating density is ensured.
Preferably, in the step (1), the needling density of the ultra-thin mesh fabric coating prefabricated body is 20 needles/cm2The needling depth is 15mm, and the density of the prepared coating is 0.18 +/-0.02 g/cm3In general, the higher the needling density is, the higher the density of the ultra-thin mesh fabric coating preform is, the appropriate density of the ultra-thin mesh fabric coating preform can make the wear-resistant coating have good mechanical properties and wear resistance; the lower density can cause the coating preform to be easy to deform, and the wear-resistant coating has poor mechanical properties, poor combination and the like; the higher density can cause too much and too much needling holes to be too dense, the densification is difficult to fill, the appearance is deteriorated, meanwhile, the uniformity of the densification is deteriorated, the carbon content is increased, and the wear resistance of the carbon ceramic coating disc after the ceramic is formed is reduced. The proper needling depth can provide good mechanical property, beautiful appearance and the like for the carbon ceramic coating disc; the low needling depth causes poor combination of the wear-resistant coating, and the phenomenon of block falling, layering and the like caused by low interlayer shear strength at the combination part of the wear-resistant coating and the carbon ceramic composite material supporting layer; too high a needling depth will result in deep and coarse needling holes, resulting in a carbon ceramic coated disc with a very poor appearance (probably due to the fact that uniform filling of the needling holes during densification is relatively difficult).
Meanwhile, in the process of exploring the technology, the following are also found: the ultra-thin mesh fabric has higher deposition efficiency and faster densification, and the excessively high density of the ultra-thin mesh fabric coating preform easily causes hole sealing at the joint in the deposition densification process and cannot be treated, so that the subsequent ceramic treatment is not thorough, or the ultra-thin mesh fabric coating preform meets the design requirement in the densification process and the support preform does not meet the requirement, so that the mechanical property of the final carbon-ceramic composite material support layer is poor.
As a further preference, in the step (3)The density of the C/C matrix of the coating disc is 1.20 +/-0.05 g/cm3. The proper density of the C/C matrix of the coating disc, the moderate size of the internal pores, the uniform pore distribution and the like are beneficial to the ceramic treatment and the acquisition of more ideal mechanical properties; the too low density of the C/C matrix of the coating disc can lead the carbon ceramic coating disc after being ceramized to have lower comprehensive mechanical property; too high density of the C/C matrix of the coating disc can lead to incomplete ceramization (pores are fine and uneven, and the hole sealing phenomenon possibly exists at the joint of the coating C/C matrix and the C/C matrix of the supporting layer), and the wear-resistant coating has higher carbon content and lower ceramic content and is not wear-resistant.
The invention relates to a preparation method of an integrally formed carbon ceramic coating disc, wherein in the step (3), the density difference of an upper layer, a middle layer and a lower layer of a C/C basal body of the coating disc is lower than 0.20g/cm3(ii) a In the preferable step (3), the density difference of the upper, middle and lower layers of the C/C substrate of the coated disc is less than 0.10g/cm3。
Preferably, in the step (4), the high-temperature siliconizing temperature of the C/C matrix of the coating disc is 1750 +/-20 ℃. In the process of high-temperature siliconizing, when the temperature is too low, the viscosity of silicon is high, the permeability is poor, and the phenomenon of pot sticking is easy to occur; when the temperature is too high, the density of the carbon ceramic coating disc is lower, particularly, the phenomenon of obvious needling holes can occur on the coating part, the wear resistance and the oxidation resistance are greatly influenced, and the comprehensive mechanical property is poorer when the temperature is higher.
The invention relates to a preparation method of an integrally formed carbon ceramic coated disc, wherein in the step (4), the density of the integrally formed carbon ceramic coated disc is 2.00-2.50g/cm3Preferably 2.30 to 2.50g/cm3The aperture ratio is 1 to 10 percent, preferably 1 to 3 percent;
the density of the carbon-ceramic composite material supporting layer is 2.00-2.50g/cm3Preferably 2.20 to 2.50g/cm3The aperture ratio is 1-10%, preferably 1-3%, and the ceramic content is 50-60 wt%, preferably 55 wt%;
the density of the wear-resistant coating is 2.10-2.60g/cm3Preferably 2.30 to 2.60g/cm3The open porosity is 1 to 8%, preferably 1 to 3%, and the ceramic content is 60 to 80 wt%, preferably 70 wt%.
The interlaminar shear strength between the wear-resistant coating and the carbon-ceramic composite material supporting layer is more than 20 MPa.
The thickness of the wear resistant coating in the finished product is preferably 2-4 mm.
The invention relates to a preparation method of an integrally formed carbon-ceramic coated disc, wherein the interlaminar shear strength of the wear-resistant coating of the carbon-ceramic coated disc and the carbon-ceramic composite material supporting layer is 27-28.5 MPa, the compressive strength of the carbon-ceramic composite material supporting layer is 385-395 MPa, the bending strength is 245-260MPa, and the impact toughness is 59-62KJ/m2。
The optimized scheme of the invention is to sequentially needle-punch 12K-PANCF (polyacrylonitrile) ultrathin mesh fabrics with certain thickness on the surface of the whole felt carbon fiber preform to prepare the coating disc preform matrix. According to the invention, the support prefabricated body is formed by continuously needling the weftless cloth and the 12K-PANCF ultrathin mesh fabric in a 1x +1y mode, and the weftless cloth is layered at 0 degree/90 degrees to prepare the support prefabricated body with higher density and mechanical property; then needling 12K-PANCF ultra-thin mesh fabrics with certain thickness on two sides of the support preform to obtain a coating disc preform substrate; subsequently, the coating disc C/C substrate is obtained through deposition or impregnation densification; finally, obtaining the carbon ceramic coating disc through high temperature infiltration (RMI). The carbon ceramic coating disc carbon ceramic composite material supporting layer keeps excellent mechanical properties of a traditional carbon ceramic disc, and the wear-resistant coating has high ceramic content, so that the carbon ceramic coating disc carbon ceramic composite material supporting layer has higher coating interlayer shear strength and wear resistance compared with a common coating disc (prepared by a slurry method or a mould pressing method). The coating prefabricated body is prepared by the innovative weaving technology, so that the coating prefabricated body has certain strength in the carbon fiber prefabricated body stage, the comprehensive mechanical property is further improved by the subsequent coating protection of densified carbon and ceramic, the coating is ensured not to fall off and be damaged no matter braking is carried out under severe working conditions of high speed, high pressure, high temperature and the like, and the wear resistance and the safety of a product are greatly improved on the basis of stable braking. The invention also innovatively utilizes the relation between the C/C density and the infiltration (RMI) temperature to further reduce the cost and improve the mechanical property.
Compared with the prior art, the invention has the following advantages:
(1) the interlayer shear strength of the joint of the carbon-ceramic coated disc wear-resistant coating and the carbon-ceramic composite material supporting layer is greater than 20MPa, the coating does not fall off and block under severe working conditions, and cracks do not expand.
(2) The friction coefficient of the carbon-ceramic coated disc has stable pressure fading resistance and heat decay resistance.
(3) The abrasion of the carbon ceramic coated disc is almost 0 after the brake pad is matched and synthesized to complete a national standard J2522 automobile bench test, and the abrasion of the carbon ceramic coated disc on the brake pad is reduced by about half compared with that of the traditional carbon ceramic disc.
(4) The invention has simple production operation, almost no increase of process steps compared with the traditional carbon ceramic plate production, low cost, simple and convenient production operation and high performance.
(5) The coating disc has high density, the aperture ratio is less than 4 percent after optimization, the aperture ratio can be less than or equal to 3 percent after further optimization, and the oxidation resistance is strong.
Drawings
FIG. 1 shows a brake disk for an automobile obtained in example 1.
Detailed Description
The present invention will be further described with reference to examples and comparative examples.
Example 1
(1) Coated disc preform substrate
The needle punching density is 20 needles/cm2And under the process of needling depth of 15mm, needling 12K-PANCF ultrathin mesh fabric on two sides of the carbon fiber support preform to prepare the ultra-thin mesh fabric with the thickness of 6mm and the density of 0.18g/cm3To prepare a coated preform of 0.43g/cm3The coated disk preform substrate of (1); (the needling mode is that the single surface is needled one layer and then the second layer is needled by rotating 90 degrees, the two layers are needled and then the second layer is transferred to the reverse side needling, and the procedures are repeated and alternated until the designed thickness and the designed density are reached)
(2) Heat treatment of preforms
Carrying out high-temperature heat treatment on the coated disc preform substrate at 2000 ℃ under the argon protection atmosphere, wherein the density change is 0.41g/cm3；
(3) Densifying of preforms
The method comprises the following steps: densifying the heat-treated coating disc preform substrate to 0.95g/cm in a chemical vapor deposition furnace under the working condition that propylene or natural gas is used as a carbon source and nitrogen is used as protective gas3(ii) a (upper and lower surface each turning 1.0mm visible light)
Secondly, the step of: turning over the coated disc and densifying to 1.20g/cm in a chemical vapor deposition furnace with propylene or natural gas as carbon source and nitrogen as protecting gas3Preparing a C/C substrate of the coating disc;
(4) forming according to the drawing
(5) High temperature siliconizing
Coating the C/C substrate of the disc in a high-temperature siliconizing furnace according to the design density of 2.45g/cm3Silicon powder is laid, and then siliconizing is carried out at high temperature at 1700 ℃ under the processes of controlling the heating and cooling rate and setting multi-section heat preservation to prepare the carbon ceramic coating disc;
in this example, the density of the upper, middle and lower three layers of the C/C substrate of the coated disk was 1.16g/cm3、1.21g/cm3、1.17g/cm3The aperture ratio is 39.76%, 35.53% and 38.95% respectively, and the density uniformity is very ideal;
the density of the prepared carbon ceramic coating disc is 2.39g/cm3The aperture ratio is 2.21 percent, and the densities of the upper layer, the middle layer and the lower layer are respectively 2.48g/cm3、2.36g/cm3、2.46g/cm3；
The interlaminar shear strength of the wear-resistant coating of the carbon-ceramic coating disc and the carbon-ceramic composite material supporting layer is up to 27.3MPa, the compressive strength of the carbon-ceramic composite material supporting layer is 385.6MPa, the bending strength of the carbon-ceramic composite material supporting layer is 245.4MPa, and the impact toughness of the carbon-ceramic composite material supporting layer is 61.3KJ/m2The carbon-ceramic composite material support layer has excellent mechanical property, and provides framework support with enough strength for the carbon-ceramic coating disc;
after the obtained carbon-ceramic coating disc is matched with and synthesized into the brake pad to complete a J2522 automobile bench test, the characteristic coefficient is 0.42, the abrasion of the carbon-ceramic coating disc is 0.003mm, and the abrasion of the brake pad is 0.395mm and 0.411mm respectively.
Example 2
EXAMPLE 2 the C/C density of the coated disc was changed to 1.30g/cm based on example 1 only3The other preparation processes are the same;
in this example, the densities of the upper, middle and lower three layers of the C/C substrate of the coated disk were 1.31g/cm3、1.28g/cm3、1.36g/cm3Opening a holeThe rate is 27.49%, 27.94% and 24.58% respectively, and the density uniformity is ideal;
the density of the prepared carbon ceramic coating disc is 2.32g/cm3The aperture ratio is 3.01 percent, and the density of the upper, middle and lower layers is 2.40g/cm respectively3、2.30g/cm3、2.34g/cm3；
The interlaminar shear strength of the wear-resistant coating of the carbon-ceramic coating disc and the carbon-ceramic composite material supporting layer is up to 28.1MPa, the compressive strength of the carbon-ceramic composite material supporting layer is 393.4MPa, the bending strength is 258.6MPa, and the impact toughness is 59.4KJ/m2The overall mechanical performance is improved compared with that of the embodiment 1;
after the obtained carbon-ceramic coated disc is matched with and synthesized into a brake pad to complete a J2522 automobile bench test, the characteristic coefficient is 0.39, the abrasion of the carbon-ceramic coated disc is 0.006mm, the abrasion of the brake pad is 0.456mm and 0.463mm respectively, and the abrasion is obviously improved compared with that of the embodiment 1, because the density of a C/C matrix of the coated disc in the embodiment is improved, the content of C in a wear-resistant coating of the carbon-ceramic coated disc is improved, the content of ceramic is reduced, and the abrasion loss of the carbon-ceramic coated disc is improved due to the reduction of the integral wear resistance; the abrasion of the brake pad is increased because the disk surface has slight scratches under severe working conditions such as high speed and high pressure, and the friction and vibration between the disks are aggravated by the slightly uneven disk surface, so that the abrasion loss of the brake pad is increased.
Example 3
EXAMPLE 3 the C/C density of the coated disc was changed to 1.10g/cm based on example 13The other preparation processes are the same;
in this example, the densities of the upper, middle and lower three layers of the C/C substrate of the coated disk were 1.06g/cm respectively3、1.12g/cm3、1.01g/cm3The aperture ratio is 47.76%, 45.06% and 51.68% respectively, and the density uniformity is general;
the density of the prepared carbon ceramic coating disc is 2.46g/cm3The aperture ratio is 3.48 percent, and the densities of the upper layer, the middle layer and the lower layer are respectively 2.54g/cm3、2.44g/cm3、2.58g/cm3In comparative example 1, the density is obviously improved, and the ceramic content of the carbon ceramic coating disc is also improved;
the obtained carbon ceramic coating disc is wear-resistant and the carbon ceramic is compoundedThe interlaminar shear strength of the composite material supporting layer is 25.0MPa, the compressive strength of the carbon-ceramic composite material supporting layer is 300.1MPa, the bending strength is 184.5MPa, and the impact toughness is 50.3KJ/m2In comparative example 1, the mechanical properties of the carbon ceramic composite material supporting layer are reduced;
after the obtained carbon-ceramic coated disc is matched with and synthesized into a brake pad to complete a J2522 automobile bench test, the characteristic coefficient is 0.43, the abrasion of the carbon-ceramic coated disc is 0.002mm, and the abrasion of the brake pad is 0.419mm and 0.415mm respectively;
in the embodiment, although the abrasion of the carbon-ceramic coating disc is slightly reduced, the abrasion of the dual brake pad is increased, and the most important point is that the mechanical property of the carbon-ceramic coating disc carbon-ceramic composite material supporting layer is reduced and the framework supporting capacity is insufficient.
Example 4
EXAMPLE 4 Only the matrix needling density of the coated disk preform was changed to 10 needles/cm based on example 12The coating of the prepared ultra-thin mesh fabric is reduced to 0.13g/cm3The other preparation processes are the same;
the main difference between this example and example 1 is that the density of the coating layer is lower when the core of the C/C substrate of the coated disc reaches the proper density, and the densities of the upper, middle and lower three layers of the C/C substrate of the coated disc are 1.08/cm3、1.23g/cm3、1.09g/cm3The content of C in the wear-resistant coating in the carbon ceramic coating disc is reduced, the content of ceramic is further improved, and the brittleness of the wear-resistant coating is correspondingly increased; and then the interlayer shear strength of the joint of the carbon ceramic coating disc wear-resistant coating and the carbon ceramic composite material supporting layer in the embodiment is reduced to 22.9 MPa.
Example 5
EXAMPLE 5 Only the substrate piercing depth of the coated disk preform was changed to 10 needles/cm based on example 12The other preparation processes are the same;
the main difference between the embodiment and the embodiment 1 is that the interlayer shear strength of the joint of the carbon ceramic coating disc wear-resistant coating and the carbon ceramic composite material supporting layer is also reduced to 22.5 MPa.
Comparative example 1
Comparative example 1 coated disc preform substrate of example 1The secondary densification is adjusted to 1.20g/cm3The other preparation processes are the same;
in this comparative example, the densities of the upper, middle and lower three layers of the coated disk C/C substrate were 1.35g/cm3、1.19g/cm3、1.10g/cm3The density of each interval has very big difference, upper and lower layer especially, and this will lead to the comprehensive decline of performance such as mechanics, frictional wear, and the difference of composition will lead to the difference of the two-sided wearing and tearing state of dish, and then the emergence of the circumstances such as aggravation vibration leads to further aggravation wearing and tearing, the potential safety hazard probably appears when serious.
Comparative example 2
Comparative example 2 the needling method in example 1 is that a layer is needled from a single side, then a second layer is needled by rotating 90 degrees, after two layers are needled, the second layer is transferred to reverse needling, the steps are repeated and alternated until the designed thickness and the designed density are adjusted to one side, and after one side is directly needled to the specified thickness and density, the reverse needling is carried out, and other preparation processes are the same;
in the comparative example, one side of the ultra-thin mesh fabric which is needled in advance is continuously pressed in the needling process of the other side, so that the thickness of the needled side in advance is reduced to a certain extent, the density of the coating is slightly increased, and the density of the coating is deviated in the integral calculation process by the other side, so that the density is low.
The density of the upper, middle and lower three layers of the coated disc C/C substrate of this comparative example was 1.27g/cm3、1.21g/cm3、1.10g/cm3The density of the upper layer and the lower layer has serious deviation, so that the component of the carbon ceramic coating disc also has deviation; in a friction and wear experiment, the abrasion of a carbon ceramic coating disc is 0.014mm, the abrasion of a brake pad is respectively 0.506mm and 0.637mm, the abrasion loss is obviously increased compared with that of the brake pad in embodiment 1, and the abrasion loss of two surfaces of the brake pad is obviously different because the two friction surfaces have large component difference and vibration is aggravated in the friction braking process, so that the abrasion loss is increased, and the component difference can also cause the difference of the friction stress states of the two surfaces, so that the difference of the abrasion conditions of the two surfaces is large.
Comparative example 3
Comparative example 3 on the basis of example 1, the high-temperature siliconizing temperature is 1600 ℃, and the other preparation processes are the same;
according to the comparative example, after high-temperature siliconizing and discharging, the carbon-ceramic coating disc is stuck inside the crucible, a great deal of silicon slag is still stuck on the surface after the crucible is damaged and the carbon-ceramic coating disc is taken out, heat dissipation holes and an air duct are completely blocked, the processing difficulty of the coating disc is extremely high, the brake disc is directly cut, the interior is found to be gray black, and the fact that silicon is not completely infiltrated into the interior to react is proved; the phenomenon is caused because the infiltration temperature is low, the viscosity of silicon liquid is very high, the infiltration capacity to the coating disc pores is poor, and after the reaction is finished, redundant silicon cannot be drawn out of a crucible to cause the quality problems of sticking a pot and the like;
comparative example 4
Comparative example 3 on the basis of example 1, only the high-temperature siliconizing temperature is 1900 ℃, and the other preparation processes are the same;
the density of the carbon ceramic coated disk prepared by the comparative example is 2.22g/cm3The aperture ratio is 12.31 percent, and very many fine pinholes appear on the surface of the carbon ceramic coating disc;
the interlayer shear strength between the coating and the core of the obtained carbon ceramic coating disc is only 17.4MPa, the compressive strength of the core is 263.3MPa, the bending strength is 170.5MPa, and the impact toughness is 45.1KJ/m2Overall mechanical properties were reduced compared to example 1;
after the obtained carbon-ceramic coating disc is matched with a synthesized brake pad to complete a J2522 automobile bench test, the abrasion of the carbon-ceramic coating disc is 0.022mm, the abrasion of the brake pad is 0.755mm and 0.781mm respectively, the abrasion loss of the disc is obviously increased, because the infiltration temperature is high, the aperture ratio is increased, the content of the coating ceramic is reduced, particularly the content of silicon is reduced, and the formed friction film is not strong enough and is easy to peel off, so that the abrasion loss is increased.
The purpose of controlling the lower-temperature infiltration is to improve the density of the carbon ceramic coating disc by comparing the embodiment 1, the comparative example 3 and the comparative example 4, wherein the lower the infiltration temperature is, the higher the density of the carbon ceramic coating disc is, and further the oxidation resistance is stronger; on the other hand, the lower the temperature, the more silicon is remained in the coating, the whole ceramic content is high, meanwhile, the silicon is beneficial to forming a friction film with certain strength, and the abrasion resistance of the carbon ceramic coating disc is greatly enhanced under the interaction of the silicon and the friction film; at the same time, 1.20g/cm3Use of coated disc C/C substrateThe lower infiltration temperature (1700 ℃) has the advantages of relatively low viscosity of the infiltration silicon liquid at the temperature, and the coating disc C/C matrix under the density has proper internal pore diameter and uniformly distributed pores, so that the silicon liquid can uniformly infiltrate into the coating disc C/C matrix to participate in reaction, and finally the carbon ceramic coating disc with relatively ideal comprehensive mechanical property and frictional wear property is prepared.
Claims (10)
1. The utility model provides an integrated into one piece carbon pottery coating dish which characterized in that: the friction coating prefabricated body and the support prefabricated body form a whole through a bonding and/or weaving process; the density of the wear-resistant coating preform is less than that of the support preform; the wear-resistant coating preform is made of a carbonaceous material, and the coating preform is reinforced by short fibers; the matrix is carburized and then ceramized to obtain a product, and the wear-resistant coating preform is converted into a wear-resistant ceramic coating after carburization and ceramization; converting the support preform into a carbon-ceramic composite material structure support layer; the ceramic content in the wear-resistant coating is more than 1.2 times of the ceramic content in the carbon-ceramic composite material supporting layer; the carbon ceramic composite material supporting layer and the wear-resistant coating form the carbon ceramic coating disc.
2. An integrally formed carbon-ceramic coated disk as claimed in claim 1, wherein:
firstly, preparing a support preform, and then preparing a wear-resistant coating preform at a preform stage through a bonding and/or weaving process to obtain a coating disc preform substrate, namely preparing the wear-resistant coating preform on at least one surface of the support preform, wherein the weaving process is selected from at least one of needling and puncture;
when the wear-resistant coating preform is prepared on 2 surfaces of the supporting preform, the preparation method comprises the following steps:
the ultra-thin mesh fabric is used as a raw material, and the ultra-thin mesh fabric is bonded to the supporting prefabricated body by adopting low-carbon-residue resin; and/or
Connecting the ultrathin mesh fabric to a supporting prefabricated body by using the ultrathin mesh fabric as a raw material and adopting a puncturing process and/or a needling process;
the puncture density of the puncture process is controlled to be 20 +/-10 needles/cm2Preferably 20. + -.5 needles/cm2(ii) a The needling density of the needling process is controlled to be 20 +/-10 needles/cm2Preferably 20. + -.5 needles/cm2The needling depth is 15 +/-10 mm, preferably 15 +/-5 mm, after 2-3 layers of needling, the other surface is replaced, and the abrasion-resistant coating prefabricated body is continuously needled, and the repeated alternation is carried out until the abrasion-resistant coating prefabricated body reaches the set thickness;
the raw material comprises 12K-PANCF ultra-thin mesh fabric; the low carbon residue type resin is selected from one of epoxy resin and phenolic resin;
avoid the large density difference of the coating preform stage caused by the continuous compression of the single side.
3. An integrally formed carbon-ceramic coated disk as claimed in claim 1, wherein:
the density of the supporting preform is 0.45 +/-0.20 g/cm3Preferably 0.55. + -. 0.10g/cm3The density of the wear-resistant coating preform is 0.18 +/-0.10 g/cm3Preferably 0.18. + -. 0.05g/cm3。
4. An integrally formed carbon-ceramic coated disk as claimed in claim 1, wherein: the thickness of the wear-resistant coating preform on one side of the support preform along the axial direction of the integrally-formed carbon ceramic coating disc is larger than 1 mm; preferably 2 to 10mm, more preferably 5 to 7 mm.
5. An integrally formed carbon-ceramic coated disk as claimed in claim 1, wherein: the method is characterized in that: the density of the integrally formed carbon ceramic coating disc is 2.00-2.50g/cm3Preferably 2.30 to 2.50g/cm3The aperture ratio is 1 to 10 percent, preferably 1 to 3 percent;
the density of the carbon-ceramic composite material supporting layer is 2.00-2.50g/cm3Preferably 2.20 to 2.50g/cm3The aperture ratio is 1-10%, preferably 1-3%, and the ceramic content is 50-60 wt%, preferably 55 wt%;
the density of the wear-resistant coating is 2.10-2.60g/cm3Preferably 2.30 to 2.60g/cm3The aperture ratio is 1-8%, preferably 1-3%, the ceramic content is 60-80 wt%, preferably 70 wt%, and the ceramic content of the wear-resistant coating is greater than that of the carbon-ceramic composite material structure support layer.
The shear strength between the wear-resistant coating and the carbon-ceramic composite material supporting layer is greater than 20 MPa.
6. A method of making an integrally formed carbon-ceramic coated disk as claimed in any one of claims 1 to 5, comprising the steps of:
(1) at a density of 0.45 + -0.20 g/cm3Preferably 0.55. + -. 0.10g/cm3The supporting prefabricated body is needled with an ultrathin mesh fabric with a certain thickness on two sides to form an ultrathin mesh fabric with the density of 0.18 +/-0.10 g/cm3Preferably 0.18. + -. 0.05g/cm3Preparing a coating disc prefabricated body matrix from the ultrathin mesh fabric coating prefabricated body;
(2) under inert atmosphere, the coating disc prefabricated body substrate is subjected to heat treatment at 1700-2200 ℃, preferably 1800-2000 ℃;
(3) densifying a coated disc preform substrate to 1.20 + -0.10 g/cm by performing a chemical vapor deposition process twice or more3First vapor deposition densifying the coated disc preform substrate to 0.95 + -0.10 g/cm3Preferably 0.95. + -. 0.05g/cm3During the second chemical vapor deposition, the disc surface direction is firstly turned, and then densification is carried out; except for the first vapor deposition, the disc surface direction needs to be adjusted in each subsequent vapor deposition until the set density is reached, and a C/C substrate of the coating disc is obtained; the deposition of the second turnplate surface is a critical step, otherwise serious density deviation quality problems can occur;
(4) siliconizing at a high temperature of 1750 +/-100 ℃, preferably 1700 +/-50 ℃, and infiltrating liquid silicon or silicon vapor into pores of a C/C matrix of the coating disc to perform silicon-carbon reaction to prepare the integrally formed carbon-ceramic coating disc with high interlaminar shear strength and high wear resistance.
7. The method of claim 6, wherein:in the step (1), the needling density of the ultra-thin mesh fabric coating prefabricated body is 20 +/-10 needles/cm2Preferably 20. + -.5 needles/cm2The needling depth is 15 +/-10 mm, preferably 15 +/-5 mm, the needle is rotated by 90 degrees after 1 layer is needled, the needle is replaced to the other surface after 2-3 layers are needled, and needling is continued, so that repeated alternation is realized, and the uniformity of needling indentation and coating density is ensured.
8. The method of claim 6, wherein: in the step (3), the density difference of the upper layer, the middle layer and the lower layer of the C/C substrate of the coating disc is less than 0.20g/cm3(ii) a In the preferable step (3), the density difference of the upper, middle and lower layers of the C/C substrate of the coated disc is less than 0.10g/cm3。
9. The method of claim 6, wherein: in the step (4), the density of the integrally formed carbon ceramic coating disc is 2.00-2.50g/cm3Preferably 2.30 to 2.50g/cm3The aperture ratio is 1 to 10 percent, preferably 1 to 3 percent;
the density of the carbon-ceramic composite material supporting layer is 2.00-2.50g/cm3Preferably 2.20 to 2.50g/cm3The aperture ratio is 1-10%, preferably 1-3%, and the ceramic content is 50-60 wt%, preferably 55 wt%;
the density of the wear-resistant coating is 2.10-2.60g/cm3Preferably 2.30 to 2.60g/cm3The open porosity is 1 to 8%, preferably 1 to 3%, and the ceramic content is 60 to 80 wt%, preferably 70 wt%.
The interlaminar shear strength between the wear-resistant coating and the carbon-ceramic composite material supporting layer is more than 20 MPa.
10. The method of claim 6, wherein: the interlaminar shear strength between the wear-resistant coating of the carbon-ceramic coating disc and the carbon-ceramic composite material supporting layer is 27-28.5 MPa, the compressive strength of the carbon-ceramic composite material supporting layer is 385-395 MPa, the bending strength is 245-260MPa, and the impact toughness is 59-62KJ/m2。
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