CN114054774B - 一种正六边形蜂窝结构增强压铸铝基刹车片及其制备方法 - Google Patents
一种正六边形蜂窝结构增强压铸铝基刹车片及其制备方法 Download PDFInfo
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Abstract
本发明公开一种正六边形蜂窝结构增强压铸铝基刹车片及其制备方法，属于交通领域。本发明所述方法根据刹车片压铸模具内部空腔形状，设计外部形状与刹车片压铸模具内腔相同的正六边形蜂窝结构填充体的三维数字模型，然后使用气雾化球形铁粉通经过激光粉床选区熔化3D打印制备获得正六边形蜂窝结构填充体，然后将正六边形蜂窝结构填充体置于刹车片压铸模具中，在高压下将熔化铝液挤入模具型腔并填充蜂窝结构的孔隙，高压下凝固冷却后从模具中取出获得刹车片。本发明工艺简单，生产效率高，制备的正六边形蜂窝结构增强压铸铝基刹车片摩擦性能优良，且能够通过改变蜂窝结构填充体的边长、壁厚、成分和铝基体成分，实现性能的有效调控，满足不同工况条件的需求。
Description
技术领域
本发明涉及一种正六边形蜂窝结构增强压铸铝基刹车片及其制备方法，属于交通领域。
背景技术
刹车片是安装在汽车、火车等交通工具制动装置上、保障安全运行的消耗型核心关键零部件。刹车片要求有合适的摩擦系数和稳定性，在制动摩擦产生高温的条件下，不与摩擦副表面发生粘结，不产生摩擦表面的剥落、擦伤、焊结及其他毁坏性的破坏；要具有良好的导热性能和耐热性能、热疲劳性能和低的线性膨胀系数、优良的耐磨性能。现有的非金属刹车片耐热性能低，铸铁刹车片强度低、导热差，粉末冶金闸片成本高，工艺过程复杂、生产周期长，效率低。
压铸生产效率高，成型件质量优良，但受到压铸温度的限制，目前通常应用于铝、镁等低熔点金属；铝导热性能好，成本低，但强度硬度低、耐磨性不足，因此通常压铸铝刹车片很少应用。
发明内容
本发明的目的在于一种正六边形蜂窝结构增强压铸铝基刹车片的制备方法，解决了在运行过程中颗粒容易剥落，耐磨性和导热性下降的问题；正六边形蜂窝结构增强压铸铝基刹车片充分利用了铝高导热和压铸高生产效率的优点，通过蜂窝结构铁相来提高闸片的耐磨性、强度硬度和摩擦性能；填充在铝基体中的连续蜂窝结构还克服了粉末冶金方法制备的复合材料闸片中，粉末颗粒与颗粒之间各自独立存在，不能形成连续分布，具体包括以下步骤：
（1）根据刹车片压铸模具内部空腔形状设计正六边形蜂窝结构填充体三维数字模型。
（2）将填充体三维数字模型导入激光粉床选区熔化3D打印系统，使用球形铁粉通过3D打印制备获得正六边形蜂窝结构填充体。
（3）将填充体置于压力铸造模具中，通过压铸在高压下将熔化后铝液挤入模具型腔并填充蜂窝结构孔隙，高压下凝固冷却后从模具中取出获得刹车片。
优选的，本发明所述步骤（1）中的正六边形蜂窝填充结构，其边长为1mm~5mm，壁厚为0.1mm~2mm。
优选的，本发明所述步骤（2）中激光选区熔化3D打印系统制备正六边形蜂窝结构填充体时，使用的气雾化铁基球形粉末直径为10~60微米，粉末成分为纯铁或含有其它合金元素的铁合金。
优选的，本发明所述步骤（3）中所述铝液为纯铝或含有其它合金元素的铝合金熔炼后获得；压铸时铝液浇铸温度为730℃~780℃，压射压力为70~90MPa、保压时间60~80s。
本发明的另一目的在于提供所述方法制备得到的正六边形蜂窝结构增强压铸铝基刹车片。
本发明的有益效果：
（1）本发明所述方法克服了粉末冶金工艺复杂、成本高、增强颗粒容易剥离的缺点，发明并制造了新型正六边形蜂窝结构增强压铸铝基刹车片。
（2）本发明所述方法充分发挥了铝高导热和压铸高生产效率的优点，通过蜂窝结构铁相来提高闸片的耐磨性、强度硬度和摩擦性能。
（3）本发明制备的正六边形蜂窝结构增强压铸铝基刹车片摩擦性能优良，且能够通过改变蜂窝结构填充体的边长、壁厚、成分和铝基体成分，实现性能的有效调控，满足不同工况条件的需求。
具体实施方式
下面结合具体实施例对本发明作进一步详细说明；实施例1~3以纯铁和纯铝为例进行说明，实施例4以合金进行说明，但本发明的保护范围并不限于所述内容，通过改变正六边形蜂窝结构铁填充体中的合金元素成分和铝基体中元素成分，可以在更大范围实现铁铝双相刹车片的性能调控。
实施例1
（1）根据压铸刹车片铸型内腔形状尺寸，建立正六边形蜂窝填充结构三维数字模型，单元体边长为1mm，壁厚为0.1mm。
（2）将三维数字模型切片离散后导入选区熔化3D打印系统中，使用原材料为直径为10~40微米的纯铁球形粉末，打印获得铁相正六边形蜂窝填充结构。
（3）将3D打印获得的正六边形蜂窝填充结构固定于刹车片压铸模具中。
（4）将熔炼后获得的纯铝液浇入模具中，通过压铸在高压下将熔化后铝液挤入模具型腔并填充蜂窝结构孔隙，高压下凝固冷却后从模具中取出获得刹车片，压铸时铝液浇铸温度为780℃，压射压力为90MPa，保压时间80s；本实施例所得正六边形蜂窝结构增强压铸铝基刹车片硬度为102.5HBW，摩擦系数为0.28。
实施例2
（1）根据压铸刹车片铸型内腔形状尺寸，建立正六边形蜂窝填充结构三维数字模型，单元体边长为3mm，壁厚为1mm。
（2）将三维数字模型切片离散后导入选区熔化3D打印系统中，使用原材料为直径为30~60微米的纯铁球形粉末，打印获得铁相正六边形蜂窝填充结构。
（3）将3D打印获得的正六边形蜂窝填充结构固定于刹车片压铸模具中。
（4）将熔炼后获得的纯铝液浇入模具中，通过压铸在高压下将熔化后铝液挤入模具型腔并填充蜂窝结构孔隙，高压下凝固冷却后从模具中取出获得刹车片，压铸时铝液浇铸温度为760℃，压射压力为80MPa，保压时间70s。本实施例所得正六边形蜂窝结构增强压铸铝基刹车片硬度为98.1HBW，摩擦系数为0.24。
实施例3
（1）根据压铸刹车片铸型内腔形状尺寸，建立正六边形蜂窝填充结构三维数字模型，单元体边长为5mm，壁厚为2mm。
（2）将三维数字模型切片离散后导入选区熔化3D打印系统中，使用原材料为直径为50~60微米的纯铁球形粉末，打印获得铁相正六边形蜂窝填充结构。
（3）将3D打印获得的正六边形蜂窝填充结构固定于刹车片压铸模具中。
（4）将熔炼后获得的纯铝液浇入模具中，通过压铸在高压下将熔化后铝液挤入模具型腔并填充蜂窝结构孔隙，高压下凝固冷却后从模具中取出获得刹车片，压铸时铝液浇铸温度为730℃，压射压力为70MPa，保压时间60s；本实施例所得正六边形蜂窝结构增强压铸铝基刹车片硬度为99.3HBW，摩擦系数为0.26。
实施例4
（1）根据压铸刹车片铸型内腔形状尺寸，建立正六边形蜂窝填充结构三维数字模型，单元体边长为3mm，壁厚为0.1mm。
（2）将三维数字模型切片离散后导入选区熔化3D打印系统中，使用原材料为直径为10~40微米的铁基球形粉末打印获得铁相正六边形蜂窝填充结构，所述铁基球形粉末成分为镍18.0 wt%，钼5.0 wt%，钴9.0 wt%，其余为铁。
（3）将3D打印获得的正六边形蜂窝填充结构固定于刹车片压铸模具中。
（4）将熔炼后获得的铝合金液浇入模具中，通过压铸在高压下将熔化后铝液挤入模具型腔并填充蜂窝结构孔隙，高压下凝固冷却后从模具中取出获得刹车片，压铸时铝合金液浇铸温度为710℃，压射压力为80MPa，保压时间50s；所述铝合金液的成分为：硅7.0wt%，其余为铝。本实施例所得正六边形蜂窝结构增强压铸铝基刹车片硬度为105.1HBW，摩擦系数为0.28。
Claims (3)
1.一种正六边形蜂窝结构增强压铸铝基刹车片的制备方法，具体包括以下步骤：
（1）根据刹车片压铸模具内部空腔形状设计正六边形蜂窝结构填充体三维数字模型；正六边形蜂窝填充结构，其边长为1mm~5mm，壁厚为0.1mm~2mm；
（2）将填充体三维数字模型导入激光粉床选区熔化3D打印系统，使用球形铁粉通过3D打印制备获得正六边形蜂窝结构填充体；所述球形铁粉为气雾化铁基球形粉末直径为10~60微米，粉末成分为纯铁或含有其它合金元素的铁合金；
（3）将填充体置于压力铸造模具中，通过压铸在高压下将熔化后铝液挤入模具型腔并填充蜂窝结构孔隙，高压下凝固冷却后从模具中取出获得刹车片。
2.根据权利要求1所述正六边形蜂窝结构增强压铸铝基刹车片的制备方法，其特征在于：步骤（3）中所述铝液为纯铝或含有其它合金元素的铝合金熔炼后获得。
3.根据权利要求1所述正六边形蜂窝结构增强压铸铝基刹车片的制备方法，其特征在于：步骤（3）中的铝液浇铸温度为730℃~780℃，压铸时压射压力为70~90MPa、保压时间60~80s。
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| CN108219746A (zh) * | 2016-12-15 | 2018-06-29 | 罗伯特·博世有限公司 | 制造增强摩擦材料的方法 |
| CN108746555A (zh) * | 2018-05-23 | 2018-11-06 | 昆明理工大学 | 一种3d打印空间结构增强铜基复合材料的制备方法 |
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| CN108219746A (zh) * | 2016-12-15 | 2018-06-29 | 罗伯特·博世有限公司 | 制造增强摩擦材料的方法 |
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