CN114292126A - Preparation method of porous ceramic locally-reinforced composite material automobile brake pad - Google Patents
Preparation method of porous ceramic locally-reinforced composite material automobile brake pad Download PDFInfo
- Publication number
- CN114292126A CN114292126A CN202210089532.1A CN202210089532A CN114292126A CN 114292126 A CN114292126 A CN 114292126A CN 202210089532 A CN202210089532 A CN 202210089532A CN 114292126 A CN114292126 A CN 114292126A
- Authority
- CN
- China
- Prior art keywords
- brake pad
- porous ceramic
- automobile brake
- composite material
- organic foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Landscapes
- Manufacture Of Alloys Or Alloy Compounds (AREA)
Abstract
The invention discloses a preparation method of a porous ceramic local reinforced composite material automobile brake pad, belongs to the field of material processing engineering, and aims to solve the technical problem of continuous local reinforced integrated forming by taking an automobile brake pad as a typical part, thereby realizing the light weight and high performance of the automobile brake pad, shortening the production period, improving the material utilization rate and prolonging the service life of the brake pad. According to the invention, an organic foam impregnation method is adopted for sintering to prepare a large-size continuous porous ceramic preform, and a liquid die forging integrated forming technology is adopted, and quantitative pouring is adopted to prepare typical workpieces such as a continuous porous ceramic local reinforced composite material automobile brake pad and the like with high size precision and good wear resistance. The invention is applied to parts with high wear resistance requirements, such as automobile brake pads, automobile hubs, automobile pistons and the like, of local reinforced composite material structures.
Description
Technical Field
The invention belongs to material processing engineering, and particularly relates to a preparation method of a porous ceramic local reinforced composite material automobile brake pad.
Background
The brake block is a key part in the automobile braking system. High tensile strength, wear resistance, heat resistance and vibration damping properties are required for high-quality automobile brake pads. In the development process of brake pads, the brake pad materials widely used at present mainly comprise common cast iron, low-alloy cast iron, common cast steel, special alloy cast steel, low-alloy forged steel, cast iron-cast steel (forged steel) composite materials and the like. The cast iron brake pad material is mainly made of gray cast iron and comprises four typical marks of HT150, HT200, HT250, HT300 and the like. The existing automobile brake pad material mainly comprises cast iron, the material is developed towards the direction of forged steel, and the strength of the special forged steel brake pad is about two times higher than that of the cast iron brake pad. However, cast iron and forged steel have the defects of long manufacturing period, poor thermal conductivity, easy generation of thermal cracks and the like, and the performance of the automobile is greatly influenced. Deformation, heat cracking and abnormal wear of the brake pads are major failure problems. The occurrence of the faults is avoided or reduced, and the selection of the brake pad material is very critical. The main solution at present is to optimize the material by adding trace elements to improve the performance of the brake pad.
With the increasing demand for light weight of automobiles, the aluminum matrix composite brake pad is applied to the automobile brake pad, for example, the American Ford company has developed a SiCp/Al aluminum matrix composite brake pad, replaces the conventional cast iron brake pad, and applies the SiCp/Al aluminum matrix composite brake pad to Lincoln Town Car in batches; lotus applied an aluminum matrix composite to front and rear wheel brake pads for sports cars (Elise). The Qihaibo, etc. adopts liquid die forging process to prepare 20% SiCpThe tensile strength of the/Al composite material reaches 320MPa, is improved by about 28 percent compared with cast iron HT250, and can completely meet the requirement of the strength index of the brake pad. Through the working condition of repeated continuous braking, SiC is foundpThe surface temperature of the brake pad made of the/Al composite material is low, and the friction coefficient is stable. In the brake wear test, the mass wear of the SiCp A composite brake pad is about 1/4 of the cast iron brake pad. In China, etc. by centrifugal castingThe process prepares the endogenous particle reinforced Mg2Si/Al composite material, in which primary crystal Si and primary crystal Mg are obtained by adding SiC during centrifugal casting2Si, alloying elements such as Cu, Ni and the like are added to strengthen the matrix, and after T6 treatment, a material with high Hardness (HRB) of 89.6 and good wear resistance can be obtained, and both the hardness and the wear resistance can meet the performance requirements of manufacturing the brake pad. The aluminum matrix composite brake disc with light weight and excellent performance is adopted to replace a cast iron brake disc, and the development direction of the future brake pad preparation is formed.
In order to seek a high-performance automobile brake pad prepared from a high-wear-resistant aluminum alloy and an aluminum-based composite material, researchers at home and abroad develop research and development and preparation and performance optimization research of related materials. The high-wear-resistance aluminum alloy materials developed at present mainly comprise particle-reinforced aluminum-based composite materials, fiber-reinforced aluminum-based composite materials and the like. Generally, SiC and Al are added2O3、ZrO2And (3) carrying out local performance enhancement on the ceramic particles and the short fibers to prepare the particle-reinforced aluminum-based composite material. However, the added ceramic particles and ceramic fibers have poor wettability and are easy to agglomerate, so that the preparation difficulty is high, and the performance of a material part is not easy to control. If a special preparation process is adopted, higher requirements are put on equipment, and the production and manufacturing cost is greatly increased. Therefore, the process for preparing and forming the aluminum-based composite material, which is simple and convenient in process operation and excellent and stable in performance, has obvious practical significance and application value, and provides a new preparation idea and research and development direction for preparing the light-weight high-wear-resistance automobile brake pad.
Disclosure of Invention
The invention aims to solve the technical problem of local reinforced integrated forming by taking an automobile brake pad as a typical part, thereby realizing the light weight and high performance of the automobile brake pad, shortening the production period, improving the material utilization rate and prolonging the service life of the brake pad. The invention adopts an organic foam impregnation method to sinter and prepare a large-size continuous porous ceramic preform, and adopts a liquid die forging integrated forming technology and quantitative pouring to prepare the continuous porous ceramic locally-reinforced composite material automobile brake pad with high dimensional precision and good wear resistance, in particular to the liquid die forging integrated forming technology of the large-size continuous porous ceramic locally-reinforced composite material automobile brake pad.
Therefore, the invention provides an efficient and simple liquid die forging integrated forming method for large-size continuous porous ceramic local reinforced aluminum alloy structural parts, which is used for preparing typical parts for producing lightweight, high-wear-resistance and high-strength continuous local reinforced composite material automobile brake pads, and expanding the engineering forming design and preparation production application of the parts in aluminum alloy composite materials, magnesium alloy composite materials and other local reinforced composite material structural parts on the basis of the typical parts.
The invention relates to a preparation method of a porous ceramic local reinforced composite material automobile brake pad, which comprises the following steps:
step one, preparation of porous ceramic preform
The porous ceramic preform is prepared by an organic foam impregnation method, and the specific process comprises the following steps:
1) the pretreatment of the organic foam comprises three processes of alkali solution treatment, surfactant treatment and binder treatment: firstly, cutting organic foam into a specified shape, placing the organic foam into 10-20 wt.% NaOH solution, soaking for 2 hours in a water bath at the constant temperature of 40-60 ℃, repeatedly kneading after soaking, washing with clear water, and airing for later use; soaking the organic foam for 1h by adopting a CMC solution with the weight percentage of 1-2 wt.%; finally, soaking the organic foam for 1h by adopting 15-20 wt.% of silica sol to prepare a ready-to-be-pasted solution for later use;
2) sequentially feeding ceramic aggregate, a sintering aid, a high-temperature binder, a low-temperature binder, a dispersing agent, a rheological agent, a surfactant and a slurry solvent, stirring for 20-40 min at the forward rotation speed of a stirring motor of 400-600 r/min, adding a defoaming agent, and stirring for 5-15 min at the reverse rotation speed of the stirring motor of 400-600 r/min; obtaining ceramic slurry; wherein, the ceramic aggregate accounts for 45 wt.% to 55 wt.% in the ceramic slurry, the sintering aid accounts for 9 wt.% to 12 wt.%, the high-temperature binder accounts for 4 wt.% to 5 wt.%, the low-temperature binder accounts for 15 wt.% to 18 wt.%, the dispersant accounts for 0.2 wt.% to 0.5 wt.%, the rheological agent accounts for 0.2 wt.% to 0.5 wt.%, the defoaming agent accounts for 0.2 wt.% to 0.5 wt.%, and the balance is distilled water;
3) extruding the organic foam treated in the step 1) to discharge air, placing the organic foam in a slurry coating mold, and integrally soaking the organic foam together with the mold into the ceramic slurry obtained in the step 2) to fully absorb the air until the air in the organic foam is completely discharged; taking out, drying, placing on a working platform, and drying; immersing the ceramic slurry again; repeatedly coating the pulp for 4-6 times; preparing and obtaining a porous ceramic blank, namely finishing organic foam slurry coating;
4) sintering the organic foam subjected to slurry coating in the step 3), wherein the specific sintering process is as follows: heating the mixture from room temperature to 200 ℃ at a heating rate of 6-7 ℃/min; then heating from 200 ℃ to 700 ℃ at the heating rate of 1 ℃/min, preserving the heat at 700 ℃ for 120min, and then heating from 700 ℃ to 1500 ℃ at the heating rate of 5 ℃/min; keeping the temperature at 1500 ℃ for 120min, cooling from 1500 ℃ to 1000 ℃ at a cooling speed of 8-9 ℃/min, and finally cooling along with a furnace to obtain a porous ceramic preform;
step two, the porous ceramic local reinforced automobile brake pad is integrally formed
And (3) integrally forming the alloy matrix and the porous ceramic prefabricated body by liquid die forging forming to prepare the porous ceramic local reinforced composite material automobile brake pad.
Further, the ceramic material is Al2O3、ZrO2SiC or TiB2。
Further, the organic foam is polyurethane foam or polyester foam.
Further, the aluminum alloy matrix is Al-Mg-Si series, Al-Mg-Si-Cu series, Al-Zn-Mg-Cu series aluminum alloy or Mg-Al-Zn series magnesium alloy.
Further, the sintering aid is silica powder or kaolin; the high-temperature binder is bentonite or talcum powder; the low-temperature binder is industrial silica sol; the dispersant is polyacrylamide aqueous solution; the rheological agent and the surfactant are carboxymethyl cellulose aqueous solution; the defoaming agent is n-octanol; the slurry solvent is distilled water.
Further, the viscosity of the ceramic slurry is 300-400 mPa.S, and the opening angle is 12% -15%.
Further, the sintering in step 4) is performed using a KJ-SJ17 high temperature lift furnace.
Further, in the ceramic slurry in the step 2), the mass ratio of the ceramic aggregate is 45-55 wt.%, the mass ratio of the sintering aid is 12 wt.%, the mass ratio of the high-temperature binder is 5 wt.%, the mass ratio of the low-temperature binder is 15 wt.%, the mass ratio of the dispersing agent is 0.2 wt.%, the mass ratio of the rheological agent and the surfactant is 0.2 wt.%, and the mass ratio of the defoaming agent is 0.5 wt.%.
Further, after the full suction in step 3), the organic foam is taken out and drained until no continuous pulp flow exists.
Further, after the organic foam is fully absorbed in the step 3), two sides of the organic foam are dried in turn, so that the coating uniformity of the slurry is ensured.
The principle of the invention is as follows: the porous ceramic preform with the local shape of the workpiece is prepared by an organic foam impregnation method, and the composite material automobile brake pad with locally enhanced performance is prepared by a liquid die forging integrated forming process. During the preparation of porous ceramic preforms, the choice of ceramic particles (Al) is mainly used2O3、ZrO2SiC or TiB2Equal powder), component proportion regulation (the optimal slurry solid phase rate is determined to be 65-75 wt.%), and optimization of the sintering process scheme improves the strength, hardness, porosity, thermal shock resistance and structural integrity of the preform so as to improve the local reinforcing effect of the preform in the aluminum-based composite material. In the process of preparing and forming the porous ceramic local reinforced composite material automobile brake pad, the liquid metal is subjected to high-temperature solidification, plastic deformation and local feeding, so that the bonding strength of the aluminum alloy matrix and the porous ceramic prefabricated body is enhanced, and the overall strength, wear resistance and service performance of the automobile brake pad are improved.
The invention has the following beneficial effects:
1) the porous ceramic preform is an important component for ensuring the high wear resistance of the automobile brake pad, the preparation process of the porous ceramic preform determines the structure and performance of the continuous porous ceramic locally-enhanced automobile brake pad, and the large-size continuous porous ceramic preform is prepared by adopting an organic foam impregnation method. The organic foam impregnation method has simple process, convenient operation and low manufacturing cost, and is an economical, practical and wide-prospect porous ceramic preparation process for preparing the high-porosity porous ceramic. The method is characterized in that by means of the three-dimensional network structure of the organic foam, the ceramic slurry is uniformly coated on the organic foam and dried, and then sintered at high temperature to prepare the large-size continuous porous ceramic with network pores. The invention selects proper organic foam, ceramic powder, solvent and additive, and can prepare large-size continuous porous ceramic preform with certain strength and high porosity through pretreatment, slurry coating and sintering.
2) The invention combines the sintering preparation of the porous ceramic preform with the liquid die forging integrated forming process, and can prepare and obtain the aluminum matrix composite material typical structural part continuously and locally reinforced by the porous ceramic. On one hand, the preparation of the porous ceramic preform ensures the continuous integrity of the reinforced ceramic on the aluminum matrix and improves the local reinforcing effect of the use performance of the aluminum matrix composite, and on the other hand, the liquid die forging integration realizes the uniform and controllable distribution of the reinforcing phase in the aluminum matrix, improves the bonding strength between the aluminum matrix and the reinforcing phase and optimizes the use performance of the aluminum matrix composite workpiece. Meanwhile, the integrated forming process is adopted in the invention, so that the near-net green production is realized, the preparation procedures are reduced, and the material and time cost are saved.
Drawings
FIG. 1 is a schematic view of an assembly of a liquid forging and forming die for an automobile brake pad; in the figure, 1-an upper template, 2-an upper die, 3-an upper die sleeve, 4-a lower die sleeve, 5-a lower die, 6-a bolt, 7-a mandril, 8-a bolt, 9-a brake block product, 10-a tray, 11-a bolt, 12-a lower die sleeve, 13-a positioning pin and 14-a lower die base plate;
FIG. 2 is a flow chart of a process for preparing a porous ceramic preform;
FIG. 3 is a pictorial view of a continuous porous ceramic preform;
FIG. 4 is a flow chart of an integrated forming process of a porous ceramic local reinforced composite material automobile brake pad;
FIG. 5 is a schematic diagram of a continuous porous ceramic partially reinforced composite material automobile brake pad.
Detailed Description
For the purpose of promoting a clear understanding of the objects, aspects and advantages of the embodiments of the invention, reference will now be made in detail to the embodiments of the present disclosure, and it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the disclosure.
The exemplary embodiments of the present invention and the description thereof are provided to explain the present invention and not to limit the present invention.
Examples
With Al2O3The air brake pad is prepared by the flow of fig. 2 and 4 by taking porous ceramic and organic foam as an example, polyurethane foam.
FIG. 2 is a flow chart of a process for preparing a porous ceramic preform, which shows the control of the structure and performance influencing factors of the porous ceramic preform, such as material selection, slurry preparation, high-temperature sintering and the like, during the preparation of the porous ceramic preform. Fig. 4 is a schematic diagram of an integrated forming process of the porous ceramic local reinforced composite material automobile brake pad, a liquid die forging forming die (fig. 1) for preparing the automobile brake pad is designed according to the size and use requirements of a workpiece of the automobile brake pad, and the forming preparation and continuous production of the porous ceramic local reinforced composite material automobile brake pad can be realized according to the procedures of alloy smelting, die preheating, liquid die forging forming and the like.
The preparation method of the porous ceramic local reinforced composite material automobile brake pad comprises the following steps:
step one, preparation of porous ceramic preform
The porous ceramic preform is prepared by an organic foam impregnation method, and the specific process comprises the following steps:
1) the surface modification is carried out on the organic foam while the hardness of the organic foam is ensured, so that the wettability and the adhesion between the organic foam and the slurry are improved, and the coating thickness of the slurry on the surface of the organic foam is increased. The pretreatment of the organic foam comprises three processes of alkali solution treatment, surfactant treatment and binder treatment: firstly, cutting organic foam into a specified shape, placing the organic foam into 10 wt.% NaOH solution, soaking for 2 hours in a water bath at the constant temperature of 60 ℃, repeatedly kneading and washing with clear water after soaking, measuring the weight loss condition after drying, and airing for later use; then soaking the organic foam for 1 hour by adopting 1 wt.% CMC solution; finally, soaking the organic foam for 1h by adopting 20 wt.% of industrial silica sol to prepare slurry for later use;
2) selecting Al2O3The powder material is used as ceramic aggregate, the silica powder and kaolin are used as sintering aids, the bentonite and the talc powder are used as high-temperature binders, the industrial silica sol is used as a low-temperature binder, the polyacrylamide aqueous solution is used as a dispersing agent, the carboxymethyl cellulose aqueous solution is used as a rheological agent and a surfactant, the n-octanol is used as a defoaming agent, and the distilled water is used as a slurry solvent. Preparing ceramic slurry according to the solid phase ratio (ceramic aggregate mass ratio of 45 wt.%), wherein the mass of a sintering aid is 12 wt.%, the mass of a high-temperature binder is 5 wt.%, the mass of a low-temperature binder is 15 wt.%, the mass of a dispersing agent is 0.2 wt.%, the mass of a rheological agent and a surfactant is 0.2 wt.%, the mass of a defoaming agent is 0.5 wt.%, and the balance is distilled water. Sequentially adding ceramic slurry ingredients according to a sintering aid, a high-temperature binder, a small amount of water, a dispersing agent, a rheological agent, a low-temperature binder and ceramic powder, supplementing water to a preset weight, stirring by virtue of a stirring motor (the rotating speed is 500r/min), adding n-octyl alcohol serving as a defoaming agent after rotating positively for 30min, and obtaining ceramic slurry with certain viscosity and fluidity (the viscosity is 300-400 mPa.S, and the opening angle is 12-15%) after rotating reversely for 10 min;
3) extruding the treated organic foam to exhaust air, placing the organic foam in a slurry coating mold, and soaking the whole mold into the prepared ceramic slurry to fully absorb the air until the air in the organic foam is completely exhausted; taking out and drying until no continuous pulp flow exists, placing the pulp on a working platform, uniformly drying the pulp by adopting pneumatic equipment, and drying the pulp again after turning over so as to ensure the uniformity of the pulp; immersing the ceramic slurry again, and hanging the slurry for 4-6 times repeatedly to ensure that the slurry is uniformly coated on the reticular structure of the organic foam and a ceramic blank layer with a certain thickness (based on completely coating the foam) is formed; preparing to obtain a porous ceramic blank, and finishing the organic foam slurry.
4) Sintering the porous ceramic preform by adopting a KJ-SJ17 high-temperature lifting furnace according to a formulated sintering process scheme to obtain the porous ceramic preform, wherein the specific sintering process is as follows: heating from room temperature to 200 ℃ at the heating rate of 6.6 ℃/min; then heating from 200 ℃ to 700 ℃ at the heating rate of 1 ℃/min, preserving the heat at 700 ℃ for 120min, and then heating from 700 ℃ to 1500 ℃ at the heating rate of 5 ℃/min; keeping the temperature at 1500 ℃ for 120min, cooling from 1500 ℃ to 1000 ℃ at a cooling speed of 8.3 ℃/min, and finally cooling along with a furnace to obtain a porous ceramic preform;
step two, the porous ceramic local reinforced automobile brake pad is integrally formed
And (3) integrally forming the alloy matrix and the porous ceramic prefabricated body by liquid die forging forming to prepare the porous ceramic local reinforced composite material automobile brake pad.
According to the using requirements of the automobile brake pad, a forming die for preparing an automobile brake pad blank is designed, and the integrated forming preparation of the porous ceramic local reinforced composite material automobile brake pad is completed according to the working procedures of smelting, preheating, forming and the like, wherein the test equipment mainly comprises a press machine, alloy smelting equipment, a die heating device and a corresponding control device, the press machine is an X323-500B type 5000KN four-column oil press, and the smelting equipment is an SDL-FZ-500 type nonferrous metal melting holding furnace.
A sintered large-size continuous porous ceramic preform was prepared according to the porous ceramic preform preparation process flow chart shown in FIG. 2, and the obtained porous ceramic preform was shown in FIG. 3. Example Al2O3High-temperature sintering preparation of porous ceramic Al with high porosity, high compressive strength and complete structure2O3Porous ceramic preform (porosity up to 55%, compressive strength up to 180.94MPa, no macrocracks).
Preparing continuous Al according to the integrated forming scheme of the porous ceramic local reinforced composite material automobile brake pad shown in figure 42O3The porous ceramic local aluminum matrix composite automobile brake pad (shown in figure 5) comprises the following specific steps: will be provided withThe liquid forging forming die of the automobile brake pad shown in FIG. 1 is arranged on a hydraulic press; starting a smelting furnace, placing the clean and dry aluminum alloy blank in the furnace after the smelting furnace is preheated, and heating and melting the aluminum alloy blank; connecting a resistance wire power supply of the forming die, setting the temperature of the die, heating, spraying graphite on the surface of the die when the temperature of the die reaches 100-200 ℃, and closing the die and continuing heating; mixing Al2O3Preheating and insulating the porous ceramic preform in a heating furnace at 200-300 ℃; refining after the aluminum alloy is completely melted; starting the hydraulic press when the temperature of the aluminum alloy melt (730 ℃) and the temperature of the die (300 ℃) reach preset values; after the die is opened, Al is firstly added2O3Putting the porous ceramic preform into a mold, pouring a certain amount of liquid aluminum alloy into the mold, closing the mold, pressurizing, maintaining the pressure for 40s, and opening the mold, thereby preparing the continuous Al through forming2O3The ceramic local reinforced aluminum alloy composite material automobile brake pad; and (4) ejecting the workpiece after the workpiece is cooled for 5min, and taking the workpiece out to perform the forming preparation of the next automobile brake pad so as to realize the continuous production of the workpiece.
Fig. 1 is a schematic view of an assembly of a liquid forging and forming die for an automobile brake pad, which shows the process principles of liquid infiltration, high-temperature forming, local feeding and the like in the liquid forging and forming process of the automobile brake pad;
as shown in fig. 1, the die is assembled on a cross beam and a workbench of a press through an upper template 1 and a lower template 14, an upper die 2 and an upper die jacket 3 form a forming die male die through bolt connection, a lower die jacket 4, a lower die 5, a tray 10 and a lower die jacket 12 form a die female die, and a cavity formed by the die female die and the male die is used for realizing the forming of molten metal under the pressure of the die during liquid forging forming. The mould is designed with a local loading feeding device, so that the brake pad part 9 can be pressurized and fed in the forming process, and the organization performance of the part and the bonding strength of the porous ceramic and the matrix are improved. After the forming die is assembled, the forming preparation of the porous ceramic local reinforced automobile brake pad is completed according to the procedures of alloy matrix smelting, die and preform preheating, liquid forging forming and the like, wherein the test equipment mainly comprises a press machine, alloy smelting equipment, a die heating device and a corresponding control device.
Compared with the prior art, the improved preparation and forming method of the porous ceramic local reinforced composite material automobile brake pad effectively solves the problems of easy deformation, thermal cracking and abnormal wear of the conventional gray cast iron brake pad, improves the problems of reinforcing phase agglomeration, poor wettability and the like of the conventional particle reinforced aluminum-based composite material, and prepares the local reinforced aluminum-based composite material automobile brake pad with light weight, good bonding strength and excellent wear resistance by combining the sintering preparation of the porous ceramic preform and the liquid die forging integrated forming process.
Al prepared by the method of this example2O3The friction coefficient of the-2A 50 composite material automobile brake pad is 0.45, the wear rate is 7.427 mg/(km.N), while the friction coefficient of the common gray cast iron is 0.56, and the wear rate is 21.827 mg/(km.N), so the composite material automobile brake pad prepared by the embodiment has excellent wear resistance. With Al2O3The shear strength of the-2A 50 composite material automobile brake pad reaches 119.63MPa, the integral bonding strength of a workpiece is higher, and the weight of the automobile brake pad is reduced by 64.71 percent compared with that of a gray cast iron automobile brake pad (Al prepared in the embodiment)2O3The weight of the 2A50 composite material automobile brake pad is 3.8-4.3Kg, and the weight of the gray cast iron automobile brake pad is 11-12 Kg).
The method realizes the continuous, stable and controllable distribution of the ceramic reinforcing phase in the aluminum alloy matrix, improves the bonding performance of the porous ceramic and the aluminum alloy matrix, and improves the performance and the service life of the automobile brake pad. By liquid die forging integrated forming, the material utilization rate is improved, the working procedures are reduced, the preparation production practice is shortened, and the production efficiency is improved. Besides aluminum-based composite material products, the method is also suitable for the preparation and production of locally reinforced typical structural products such as magnesium alloy composite materials and nickel-based high-temperature composite materials, and has important engineering significance and application value for performance optimization, light-weight production and the like of typical structural products.
Claims (10)
1. A preparation method of a porous ceramic local reinforced composite material automobile brake pad is characterized by comprising the following steps:
step one, preparation of porous ceramic preform
The porous ceramic preform is prepared by an organic foam impregnation method, and the specific process comprises the following steps:
1) the pretreatment of the organic foam comprises three processes of alkali solution treatment, surfactant treatment and binder treatment: firstly, cutting organic foam into a specified shape, placing the organic foam into 10-20 wt.% NaOH solution, soaking for 2 hours in a water bath at the constant temperature of 40-60 ℃, repeatedly kneading after soaking, washing with clear water, and airing for later use; soaking the organic foam for 1h by adopting a CMC solution with the weight percentage of 1-2 wt.%; finally, soaking the organic foam for 1h by adopting 15-20 wt.% of silica sol to prepare a ready-to-be-pasted solution for later use;
2) sequentially feeding ceramic aggregate, a sintering aid, a high-temperature binder, a low-temperature binder, a dispersing agent, a rheological agent, a surfactant and a slurry solvent, stirring for 20-40 min at the forward rotation speed of a stirring motor of 400-600 r/min, adding a defoaming agent, and stirring for 5-15 min at the reverse rotation speed of the stirring motor of 400-600 r/min; obtaining ceramic slurry; wherein, the ceramic aggregate accounts for 45 wt.% to 55 wt.% in the ceramic slurry, the sintering aid accounts for 9 wt.% to 12 wt.%, the high-temperature binder accounts for 4 wt.% to 5 wt.%, the low-temperature binder accounts for 15 wt.% to 18 wt.%, the dispersant accounts for 0.2 wt.% to 0.5 wt.%, the rheological agent accounts for 0.2 wt.% to 0.5 wt.%, the defoaming agent accounts for 0.2 wt.% to 0.5 wt.%, and the balance is distilled water;
3) extruding the organic foam treated in the step 1) to discharge air, placing the organic foam in a slurry coating mold, and integrally soaking the organic foam together with the mold into the ceramic slurry obtained in the step 2) to fully absorb the air until the air in the organic foam is completely discharged; taking out, drying, placing on a working platform, and drying; immersing the ceramic slurry again; repeatedly coating the pulp for 4-6 times; preparing and obtaining a porous ceramic blank, namely finishing organic foam slurry coating;
4) sintering the organic foam subjected to slurry coating in the step 3), wherein the specific sintering process is as follows: heating the mixture from room temperature to 200 ℃ at a heating rate of 6-7 ℃/min; then heating from 200 ℃ to 700 ℃ at the heating rate of 1 ℃/min, preserving the heat at 700 ℃ for 120min, and then heating from 700 ℃ to 1500 ℃ at the heating rate of 5 ℃/min; keeping the temperature at 1500 ℃ for 120min, cooling from 1500 ℃ to 1000 ℃ at a cooling speed of 8-9 ℃/min, and finally cooling along with a furnace to obtain a porous ceramic preform;
step two, the porous ceramic local reinforced automobile brake pad is integrally formed
And (3) integrally forming the alloy matrix and the porous ceramic prefabricated body by liquid die forging forming to prepare the porous ceramic local reinforced composite material automobile brake pad.
2. The method for preparing the porous ceramic locally reinforced composite material automobile brake pad according to claim 1, wherein the ceramic material is Al2O3、ZrO2SiC or TiB2。
3. The method of claim 1, wherein the organic foam is polyurethane foam or polyester foam.
4. The method for preparing the porous ceramic local reinforced composite material automobile brake pad according to claim 1, wherein the aluminum alloy matrix is Al-Mg-Si series, Al-Mg-Si-Cu series, Al-Zn-Mg-Cu series aluminum alloy or Mg-Al-Zn series magnesium alloy.
5. The method for preparing the porous ceramic locally reinforced composite material automobile brake pad according to claim 1, wherein the sintering aid is silica powder or kaolin; the high-temperature binder is bentonite or talcum powder; the low-temperature binder is industrial silica sol; the dispersant is polyacrylamide aqueous solution; the rheological agent and the surfactant are carboxymethyl cellulose aqueous solution; the defoaming agent is n-octanol; the slurry solvent is distilled water.
6. The method for preparing the porous ceramic locally reinforced composite material automobile brake pad according to claim 1, wherein the viscosity of the ceramic slurry is 300-400 mPa.S, and the opening angle is 12-15%.
7. The method for preparing the porous ceramic locally reinforced composite material automobile brake pad according to claim 1, wherein the sintering in the step 4) is performed by using a KJ-SJ17 high temperature lift furnace.
8. The method for preparing the porous ceramic locally reinforced composite material automobile brake pad according to claim 1, wherein the ceramic aggregate ratio in the ceramic slurry in the step 2) is 45 wt.% to 55 wt.%, the sintering aid mass ratio is 12 wt.%, the high-temperature binder mass ratio is 5 wt.%, the low-temperature binder mass ratio is 15 wt.%, the dispersing agent mass ratio is 0.2 wt.%, the rheological agent and the surfactant mass ratio is 0.2 wt.%, and the defoaming agent mass ratio is 0.5 wt.%.
9. The method for preparing the porous ceramic locally reinforced composite material automobile brake pad according to claim 1, wherein the organic foam is taken out after full absorption in the step 3) and is drained until no continuous pulp flow exists.
10. The method for preparing the porous ceramic locally reinforced composite material automobile brake pad according to claim 1, wherein the organic foam is blown dry on two sides in turn after saturated absorption in the step 3), so that the uniformity of slurry coating is ensured.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210089532.1A CN114292126A (en) | 2022-01-25 | 2022-01-25 | Preparation method of porous ceramic locally-reinforced composite material automobile brake pad |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210089532.1A CN114292126A (en) | 2022-01-25 | 2022-01-25 | Preparation method of porous ceramic locally-reinforced composite material automobile brake pad |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN114292126A true CN114292126A (en) | 2022-04-08 |
Family
ID=80976679
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210089532.1A Pending CN114292126A (en) | 2022-01-25 | 2022-01-25 | Preparation method of porous ceramic locally-reinforced composite material automobile brake pad |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN114292126A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114804828A (en) * | 2022-04-26 | 2022-07-29 | 鞍钢集团矿业有限公司 | Porous ceramic prepared from mine solid waste and preparation method thereof |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103952582A (en) * | 2014-04-28 | 2014-07-30 | 上海大学 | Preparation method of aluminum-based composite material applied to light brake disc |
| CN105016758A (en) * | 2015-07-09 | 2015-11-04 | 余姚市海博机械有限公司 | Abrasion-resistance ceramic material, and ceramic-partially-reinforced aluminum-based composite material and preparation method thereof |
| US20190016639A1 (en) * | 2016-01-11 | 2019-01-17 | Zhangjiagang Institute Of Industrial Technologies Soochow University | Barium titanate foam ceramic/thermosetting resin composites and preparation method thereof |
| CN109261941A (en) * | 2018-10-17 | 2019-01-25 | 西安交通大学 | A kind of preparation method of the holey ceramics enhancing compound brake shoes of steel-based |
| CN111992694A (en) * | 2020-08-24 | 2020-11-27 | 西安工业大学 | Configurable SiCp/Al-based composite material and preparation method thereof |
| US20210171403A1 (en) * | 2017-11-13 | 2021-06-10 | Ningbo Highrise New Material Co.,Ltd. | Wear-resistant material, locally-reinforced light metal matrix composites and manufacturing method |
-
2022
- 2022-01-25 CN CN202210089532.1A patent/CN114292126A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103952582A (en) * | 2014-04-28 | 2014-07-30 | 上海大学 | Preparation method of aluminum-based composite material applied to light brake disc |
| CN105016758A (en) * | 2015-07-09 | 2015-11-04 | 余姚市海博机械有限公司 | Abrasion-resistance ceramic material, and ceramic-partially-reinforced aluminum-based composite material and preparation method thereof |
| US20190016639A1 (en) * | 2016-01-11 | 2019-01-17 | Zhangjiagang Institute Of Industrial Technologies Soochow University | Barium titanate foam ceramic/thermosetting resin composites and preparation method thereof |
| US20210171403A1 (en) * | 2017-11-13 | 2021-06-10 | Ningbo Highrise New Material Co.,Ltd. | Wear-resistant material, locally-reinforced light metal matrix composites and manufacturing method |
| CN109261941A (en) * | 2018-10-17 | 2019-01-25 | 西安交通大学 | A kind of preparation method of the holey ceramics enhancing compound brake shoes of steel-based |
| CN111992694A (en) * | 2020-08-24 | 2020-11-27 | 西安工业大学 | Configurable SiCp/Al-based composite material and preparation method thereof |
Non-Patent Citations (3)
| Title |
|---|
| 刘静安等 编著: "《铝合金锻造技术》", 30 June 2012, 冶金工业出版社 * |
| 王晓敏 主编: "《工程材料学（第4版）》", 31 July 2017, 哈尔滨工业大学出版社 * |
| 程远胜等: "局部增强铝基复合材料挤压铸造一体化成形技术", 《特种铸造及有色合金》 * |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114804828A (en) * | 2022-04-26 | 2022-07-29 | 鞍钢集团矿业有限公司 | Porous ceramic prepared from mine solid waste and preparation method thereof |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN100453206C (en) | Process of making oil cylinder body and cover with aluminium alloy | |
| CN104235237B (en) | Brake disc made of carborundum foamed ceramics/aluminum alloy composite materials and production method of road vehicle brake disc | |
| CN109112444B (en) | A kind of silicon carbide whisker reinforced aluminum matrix composites isothermal multiway forging method | |
| CN106735225B (en) | A method of being injected into shape forging aluminium alloy brake disc brake drum | |
| CN103381479A (en) | Method for manufacturing aluminium hub of large bus | |
| CN101020201A (en) | Semi-solid multi-blank extruding process and apparatus for forming double-layer composite pipe | |
| CN108642314B (en) | Utilize the method for the SiCp/Al composite material preparation cluster type aluminum matrix composite of recycling | |
| CN106499741A (en) | Foamed ceramics strengthens light metal composite friction clutch disc, brake disc | |
| WO2017114079A1 (en) | Method for preparing automobile supercharging turbine | |
| CN102689161B (en) | Liquid die-forging and rolling combined forming method for 7075 aluminum alloy irregular-section large-size annular piece | |
| CN103042195A (en) | Extrusion casting manufacture method of piston with reinforced pseudo-alloy circular groove | |
| CN109092957A (en) | A kind of shaft sleeve parts part thixoextruding method | |
| CN105200276A (en) | Method for manufacturing pseudo-alloy reinforced composite material piston with internal cooling oil cavity | |
| CN114292126A (en) | Preparation method of porous ceramic locally-reinforced composite material automobile brake pad | |
| CN104624914B (en) | Radially forging strain provocation method prepares the Semi-solid Process of engine aluminum alloy camshaft | |
| CN108677051A (en) | The method for preparing cluster type aluminum matrix composite using the SiCp/Al composite materials of recycling | |
| CN104308120B (en) | Method for manufacturing automobile control arm body blank | |
| CN103725909B (en) | The forging of a kind of powder LP-mode is for the method for aluminium alloy | |
| WO2019080100A1 (en) | Silicon carbide aluminum-based composite structure element and fabrication method for silicon carbide-reinforced prefab | |
| CN108642315B (en) | Method for preparing cluster type aluminum matrix composite material by utilizing recovered SiCp/Al composite material | |
| CN107138708A (en) | Integrated die forging process | |
| CN102029369A (en) | Method for preparing SiC particle-aluminum alloy composite material cylinder liner | |
| CN111390149B (en) | Casting ladle for casting aluminum alloy | |
| CN104475697B (en) | Chopped fiber/SiCpstrengthen the semisolid preparation technology of foamed aluminium radical bearing shell | |
| CN103433466A (en) | Aluminum alloy liquid forging mould and combined forming method of starter outer shell |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |