CN115094345B - 一种高铁制动闸片用弹性垫片材料的制备方法 - Google Patents
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Abstract
一种高铁制动闸片用弹性垫片材料的制备方法,属于金属材料领域。本发明按质量分数C:0.08‑0.12%;Mn:2.8‑3.2%;Cr:12.8‑13.2%;Mo:1.4‑1.6%;W:2.9‑3.1%;Zr:0.02‑0.05%;V:0.18‑0.22%,余量为Fe进行配料,然后采用真空感应熔炼和电渣重熔双联工艺熔炼得到铸锭,控制杂质元素S≤0.005%,P≤0.005%,氮和氧均小于20ppm,再通过锻造、热轧、酸洗、退火、冷轧、热处理工序得到用于制作垫片的板材成品。该材料具有优异的压缩疲劳性能和高温强度,将其作为高铁闸片的弹性垫片具有高的可靠性和安全性。
Description
技术领域
本发明属于金属材料领域,涉及一种高铁制动闸片用弹性垫片材料的制备方法。
背景技术
高速列车制动有电阻制动、磁轨制动、涡流制动、摩擦制动等多种方式,其中摩擦制动是不可缺少的。摩擦制动方式是通过摩擦把动能转化为热能,然后消散于大气。高速列车的摩擦制动通常采用的是盘式制动方式,利用制动盘和制动闸片间的相互摩擦作用达到消耗列车动能的目的,这两个部件的性能成为一个关系到列车运行安全的重要方面。随着列车运营速度的不断提升,对制动闸片结构、摩擦材料提出了更高的要求。目前高铁或动车用制动闸片的基本结构组元主要包括粉末冶金铜基复合材料摩擦块、钢背、弹簧卡扣、弹性垫片等,其中弹性垫片位于摩擦块和钢背之间,其结构呈现蝶形,不同的厂家弹性垫片的结构尺寸略有不同,但其作用是相同的,即在摩擦块与制动盘接触制动过程中,摩擦块可以依靠垫片的弹性作用而产生浮动式调节,能够自适应三维度调节摩擦面的平面度,使得闸片在制动过程中尽可能减少偏磨现象发生。
蝶形弹性垫片在制动过程中其工作温度最高可以达到500℃,因此要求其在在该温度下长时间工作不能产生变形,也就是说要求蝶形垫片在其寿命周期内一直保持不变的高度,以保证其弹性性能。垫片高的性能要求也对垫片材料的性能提出了高的要求,要求其在500到600℃范围内具有优异的压缩疲劳性能,另外考虑其成本,通常要求其为铁基合金,现有垫片材料性价比较差,急需研发新的垫片材料。
发明内容
本发明目的在于提供一种在500到600℃范围内具有优异的压缩疲劳性能、性价比高的垫片材料。
一种高铁制动闸片用弹性垫片材料的制备方法,其特征在于:材料质量分数为C:0.08-0.12%;Mn:2.8-3.2%;Cr:12.8-13.2%;Mo:1.4-1.6%;W:2.9-3.1%;Zr:0.02-0.05%;V:0.18-0.22%;S≤0.005%;P≤0.005%;氮和氧均小于20ppm,余量为Fe,最终形态为板材,板材的厚度按实际需要决定。
如上所述高铁制动闸片用弹性垫片材料的制备方法,其特征在于:具体的制造工艺及要求如下:
(1)采用真空感应熔炼和电渣重熔双联工艺进行合金锭的熔炼,合金元素质量分数C:0.08-0.12%;Mn:2.8-3.2%;Cr:12.8-13.2%;Mo:1.4-1.6%;W:2.9-3.1%;Zr:0.02-0.05%;V:0.18-0.22%,余量为Fe,另外通过控制原材料纯度、感应熔炼真空度和电渣工艺常规方法使得合金锭中S≤0.005%;P≤0.005%;氮和氧均小于20ppm;
(2)将电渣锭进行锻造开坯和热轧成一定厚度的板材,板材的厚度为2.5~3.5mm;
(3)将热轧后的板材进行酸洗去氧化皮,然后进行退火,出炉空冷,退火后再进行冷轧,冷轧的厚度为最终需要的厚度;
(4)冷轧后的板材进行性能热处理,将经过性能热处理的板材冲压成需要尺寸的弹性垫片,即得到成品。
进一步地,步骤(2)所述锻造和热轧的起始温度为1100±10℃,终止为880±10℃。
进一步地,步骤(3)所述退火的温度为850~900℃,保温2~4小时,然后随炉冷却到500~550℃。
进一步地,步骤(4)所述热处理工艺范围为:在1050-1080℃进行固溶淬火,固溶的保温时间为带板材的厚度值×(1~1.2)、单位为min,选择油淬或气淬,淬火后在650~680℃范围内进行回火,回火的保温时间为1~2小时。采用上述成分和制备工艺制备的板材具有优异的抗压缩疲劳性能和强韧性,能够大幅度提高闸片的使用寿命和可靠性。
本发明设计合金成分的主要机理是在理论计算和模拟的基础上,在Fe基体中加入一定含量的C、Mn、Cr、Mo、W、Zr、V等常规元素,通过严格控制其含量以及热处理,可以在基体形成马氏体和铁素体两相,两相的体积比例为48%:52%,在两相基体上弥散分布着三种强化相,分别为W0.4Fe0.3Mo0.1Cr0.1Mn0.05Nb0.05合金相,其含量为6-6.5wt%,尺寸为0.5~1微米;(Cr12Mo6Fe3Mn1Zr1)C6相,其含量为2-3wt%;尺寸为1-1.5微米;(W2.6Fe1.2Mo1.2V)C相,其含量为2-2.5wt%,尺寸为1-1.3微米。铁素体和马氏体同时存在,二者比例接近,可以减少因马氏体板条高温分解引起垫片的强度和弹性下降,同时三种相呈弥散分布在两相基体中,可以进一步保证垫片在500℃长时间工作持续保持高的强度和弹性。经测试,采用本发明材料加工的各种形状的弹性垫片,在500℃压下垫片高度的20%-30%(实际应用时压下量约为高度的5-10%)并保持500小时,测试完成后垫片仍能恢复原来的高度,说明其具有优异的抗压缩疲劳性能和高温持久性能。
具体实施方式
实施例1
制备0.8mm厚的垫片板材
第一步,采用真空感应熔炼和电渣重熔双联工艺进行合金锭的熔炼,合金锭的成分为C:0.08%;Mn:2.8%;Cr:12.8%;Mo:1.4%;W:2.9%;Zr:0.02%;V:0.18%,余量为Fe,通过控制原材料纯度、感应熔炼真空度和电渣工艺等常规方法使得合金锭中S≤0.005%;P≤0.005%;氮和氧均小于20ppm;
第二步,将电渣锭进行锻造开坯和热轧成一定厚度的板材,板材的厚度为2.5mm,锻造和热轧的起始温度为1100±10℃,终止为880±10℃。
第三步,将热轧后的板材进行酸洗去氧化皮,然后进行退火,退火的温度为850℃,保温2小时,然后随炉冷却到500℃,出炉空冷,退火后再进行冷轧,冷轧的厚度为0.8mm;
第四步,冷轧后的板材进行性能热处理,工艺范围为:在1050℃进行固溶淬火,固溶的保温时间为1min,选择油淬,淬火后在650℃进行回火,回火的保温时间为1小时。将经过性能热处理的板材冲压成需要尺寸的弹性垫片,即得到成品。
实施例2
制备0.6mm厚的垫片板材
第一步,采用真空感应熔炼和电渣重熔双联工艺进行合金锭的熔炼,合金锭元素的含量为C:0.12%;Mn:3.2%;Cr:13.2%;Mo:1.6%;W:3.1%;Zr:0.05%;V:0.22%,余量为Fe,另外通过控制原材料纯度、感应熔炼真空度和电渣工艺等常规方法使得合金锭中S≤0.005%;P≤0.005%;氮和氧均小于20ppm;
第二步,将电渣锭进行锻造开坯和热轧成一定厚度的板材,板材的厚度为3.5mm,锻造和热轧的起始温度为1100±10℃,终止为880±10℃。
第三步,将热轧后的板材进行酸洗去氧化皮,然后进行退火,退火的温度为900℃,保温4小时,然后随炉冷却到550℃,出炉空冷,退火后再进行冷轧,冷轧的厚度为0.6mm;
第四步,冷轧后的板材进行性能热处理,工艺范围为:在1080℃进行固溶淬火,固溶的保温时间为2min,选择油淬或气淬,淬火后在680℃范围内进行回火,回火的保温时间为2小时。将经过性能热处理的板材冲压成需要尺寸的弹性垫片,即得到成品。
Claims (5)
1.一种高铁制动闸片用弹性垫片材料,其特征在于:材料质量分数为C: 0.08-0.12%;Mn:2.8-3.2%;Cr: 12.8-13.2%; Mo:1.4-1.6%;W:2.9-3.1%;Zr:0.02-0.05%;V :0.18-0.22%; S≤0.005%;P≤0.005%;氮和氧均小于20ppm,余量为Fe,最终形态为板材,板材的厚度按实际需要决定;
在基体形成马氏体和铁素体两相,两相的体积比例为48%:52%,在两相基体上弥散分布着三种强化相,分别为W0.4Fe0.3Mo0.1Cr0.1Mn0.05Nb0.05合金相,其含量为6-6.5wt%,尺寸为0.5~1微米;(Cr12Mo6Fe3Mn1Zr1)C6相,其含量为2-3wt%;尺寸为1-1.5微米;(W2.6Fe1.2Mo1.2V)C相,其含量为2-2.5wt%,尺寸为1-1.3微米;
经测试,采用本发明材料加工的各种形状的弹性垫片,在500℃压下垫片高度的20%-30%并保持500小时,测试完成后垫片仍能恢复原来的高度,说明其具有优异的抗压缩疲劳性能和高温持久性能。
2.如权利要求1所述高铁制动闸片用弹性垫片材料的制备方法,其特征在于:具体的制造工艺及要求如下:
(1)采用真空感应熔炼和电渣重熔双联工艺进行合金锭的熔炼,合金元素质量分数C:0.08-0.12%;Mn:2.8-3.2%;Cr: 12.8-13.2%; Mo:1.4-1.6%;W:2.9-3.1%;Zr:0.02-0.05%;V :0.18-0.22%,余量为Fe,另外通过控制原材料纯度、感应熔炼真空度和电渣工艺常规方法使得合金锭中S≤0.005%;P≤0.005%;氮和氧均小于20ppm;
(2)将电渣锭进行锻造开坯和热轧成一定厚度的板材,板材的厚度为2.5~3.5mm;
(3)将热轧后的板材进行酸洗去氧化皮,然后进行退火,出炉空冷,退火后再进行冷轧,冷轧的厚度为最终需要的厚度;
(4)冷轧后的板材进行性能热处理,将经过性能热处理的板材冲压成需要尺寸的弹性垫片,即得到成品。
3.如权利要求2所述高铁制动闸片用弹性垫片材料的制备方法,其特征在于:步骤(2)所述锻造和热轧的起始温度为1100±10℃,终止为880±10℃。
4.如权利要求2所述高铁制动闸片用弹性垫片材料的制备方法,其特征在于:步骤(3)所述退火的温度为850~900℃,保温2~4小时,然后随炉冷却到500~550℃。
5.如权利要求2所述高铁制动闸片用弹性垫片材料的制备方法,其特征在于:步骤(4)所述热处理工艺范围为:在1050-1080℃进行固溶淬火,固溶的保温时间为带板材的厚度值×(1~1.2)、单位为min,选择油淬或气淬,淬火后在650~680℃范围内进行回火,回火的保温时间为1~2小时。
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CN113737093B (zh) * | 2021-08-18 | 2022-05-03 | 北京科技大学 | 一种冰刀刀背用带材及其制备方法 |
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