CN115637354A - Forming method and forming equipment for rare earth aluminum carbon silicon brake disc - Google Patents
Forming method and forming equipment for rare earth aluminum carbon silicon brake disc Download PDFInfo
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- CN115637354A CN115637354A CN202211130450.3A CN202211130450A CN115637354A CN 115637354 A CN115637354 A CN 115637354A CN 202211130450 A CN202211130450 A CN 202211130450A CN 115637354 A CN115637354 A CN 115637354A
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Abstract
The invention provides a molding method and molding equipment of a rare earth aluminum carbon silicon brake disc. The molding equipment comprises a smelting chamber, a casting chamber, a vacuum unit and a smelting power supply, wherein the smelting chamber and the casting chamber are connected through a flap valve and are respectively connected with the vacuum unit; the smelting power supply is connected with the smelting chamber; a first feeding mechanism, a second feeding mechanism and a third feeding mechanism are arranged on the smelting chamber; a crucible and a lifting temperature measuring component are arranged in the smelting chamber, and a heating induction coil connected with a smelting power supply is arranged on the outer surface of the crucible; the crucible is respectively connected with the first feeding mechanism, the second feeding mechanism and the third feeding mechanism through vacuum valves; the lifting temperature measuring component automatically lifts to be far away from the crucible or enter the crucible and is connected with a smelting power supply. The invention can realize the low-cost and mass production of the rare earth aluminum carbon silicon brake disc.
Description
Technical Field
The invention relates to the technical field of brake discs, in particular to a molding method and molding equipment of a rare earth aluminum carbon silicon brake disc.
Background
The aluminum-based composite material has high wear resistance, high specific strength, high specific rigidity and good heat conductivity, and is widely applied to the fields of aerospace, aviation, electronics, automobiles, rail transit, military industry and the like.
In recent years, some developed countries use silicon carbide powder as a reinforcement to be added into aluminum alloy to obtain an aluminum-based ceramic composite material, and the aluminum-based ceramic composite material is applied to products such as automobile brake discs and rail transit brake discs. However, the aluminum-based ceramic composite material requires the use of a large amount of silicon carbide powder, increasing the manufacturing cost.
Under the leading of light weight of rail transit in China, in order to realize the localization of brake discs, a low-cost forming method and forming equipment of rare earth aluminum carbon silicon brake discs are needed to be developed.
Disclosure of Invention
The invention aims to provide a forming method and forming equipment of a rare earth aluminum carbon silicon brake disc, which are used for realizing low-cost and mass production of the rare earth aluminum carbon silicon brake disc, and the prepared rare earth aluminum carbon silicon brake disc has good mechanical properties. The specific technical scheme is as follows:
in a first aspect, the present invention provides a method for forming a brake disc made of rare earth aluminum carbon silicon, comprising the following steps:
step S1, preparing modified silicon carbide powder
Adding a rare earth magnesium compound used for coating the surface of the alpha silicon carbide into the alpha silicon carbide, and activating the coated alpha silicon carbide to prepare modified silicon carbide powder;
step S2, preparing rare earth aluminum silicon magnesium alloy
Mixing an aluminum alloy ingot and a synergist, and smelting under a vacuum condition to obtain a melt rare earth aluminum silicon magnesium alloy, wherein the rare earth aluminum silicon magnesium alloy comprises the following chemical components in percentage by mass: 6.5 to 7.5 percent of Si, 0.6 to 0.7 percent of Mg, 0.1 to 0.2 percent of Ti, 0.04 to 0.07 percent of Be, less than 0.5 percent of Re and the balance of Al;
s3, preparing the rare earth aluminum carbon silicon brake disc
Firstly, adding the modified silicon carbide powder into the melt rare earth aluminum silicon magnesium alloy prepared in the step S2, wherein the mass ratio of the modified silicon carbide powder to the rare earth aluminum silicon magnesium alloy is not higher than 1:3, and stirring and refining the mixture under a vacuum condition to prepare a melt rare earth aluminum carbon silicon composite material;
and secondly, pouring the rare earth aluminum silicon magnesium alloy into a forming die under the vacuum condition, and forming under the vacuum condition and the pouring temperature to obtain the rare earth aluminum carbon silicon brake disc.
Further, in step S1, the activation treatment includes drying and high-temperature baking treatment of the coated α -silicon carbide;
and after the activation treatment, the prepared modified silicon carbide powder is cooled, subjected to dust collection, screened, detected and packaged.
Further, the particle size of the modified silicon carbide powder particles prepared in step S1 is 5 to 100 μm.
Further, the step S3 further includes post-treatment, wherein the post-treatment includes sequentially performing demolding, heat treatment, processing detection and warehousing treatment on the molded rare earth aluminum carbon silicon brake disc.
Further, in step S3, the stirring speed is not lower than 500rpm, the refining temperature is 560-610 ℃, and the casting temperature is 680-710 ℃.
Further, in steps S2-S3, the vacuum condition is less than 10Pa.
In a second aspect, the invention provides a molding device adopted by the molding method of the rare earth aluminum carbon silicon brake disc, which comprises a smelting chamber, a casting chamber, a vacuum unit and a smelting power supply, wherein the smelting chamber and the casting chamber are connected through a flap valve and are respectively connected with the vacuum unit through a vacuum pipeline; the smelting power supply is connected with the smelting chamber;
a first feeding mechanism for feeding aluminum alloy ingots into the smelting chamber, a second feeding mechanism for feeding a synergist into the smelting chamber and a third feeding mechanism for feeding modified silicon carbide powder into the smelting chamber are arranged on the smelting chamber;
a crucible and a lifting temperature measuring component are arranged in the smelting chamber, and a heating induction coil connected with a smelting power supply is arranged on the outer surface of the crucible; the crucible is respectively connected with the first feeding mechanism, the second feeding mechanism and the third feeding mechanism through vacuum valves; the lifting temperature measuring component automatically lifts to be far away from the crucible or enter the crucible and is connected with a smelting power supply;
and a stirring mechanism is arranged on the smelting chamber, and the stirring end of the stirring mechanism is arranged in the crucible.
Further, a forming mold, a sand box and a lifting mechanism are arranged in the casting chamber, the sand box is arranged on the lifting mechanism, and the forming mold is arranged on the sand box and corresponds to the flap valve; the forming mold is provided with a first temperature thermocouple, the inner wall of the casting chamber is provided with a heating part, and the heating part is connected with the first temperature thermocouple and is used for heating the forming mold to the pouring temperature.
Further, the third feeding mechanism comprises a charging barrel, a screw feeding part and an isolating ball valve for connecting the charging barrel and the screw feeding part;
a vibration component is arranged in the charging barrel and used for conveying the modified silicon carbide powder into the screw feeding component in a vibration state;
the screw feeding part comprises a feeding pipe and a feeding screw arranged in the feeding pipe, and the feeding pipe is connected with the charging barrel through an isolation ball valve; and a heater for heating the feeding pipe and a second temperature thermocouple connected with the heater are arranged on the outer wall of the feeding pipe.
Furthermore, the stirring mechanism is provided with a dustproof component, the stirring end of the stirring mechanism is provided with a flow sensor, and the flow sensor is connected with a motor in the stirring mechanism.
The technical scheme of the invention at least has the following beneficial effects:
(1) According to the forming method of the rare earth aluminum carbon silicon brake disc, the modified silicon carbide powder prepared by activation in the step S1 is spherical-like silicon carbide powder, so that the wettability of the modified silicon carbide powder on a melt rare earth aluminum silicon magnesium alloy can be improved, the microcosmic stress concentration of the formed rare earth aluminum carbon silicon brake disc can be reduced, and the mechanical property of the product is improved. In addition, the particle size distribution range of the modified silicon carbide powder is relatively narrow, and the modified silicon carbide powder belongs to silicon carbide powder with ideal particle size distribution, so that the molded rare earth aluminum carbon silicon brake disc has more uniform mechanical properties. In the step S2, the melt rare earth aluminum silicon magnesium alloy is prepared by adopting the synergist and the aluminum alloy ingot, the use of the synergist is beneficial to improving the wettability of the melt rare earth aluminum silicon magnesium alloy on the modified silicon carbide powder in the step S3, and meanwhile, the modification effect of the product is improved, so that the crystal grains of the product are refined, and the particles of the modified silicon carbide powder are distributed in the product more uniformly. In the step S3, the mass ratio of the modified silicon carbide powder to the rare earth aluminum silicon magnesium alloy is not higher than 1:3, so that the manufacturing cost is greatly reduced.
(2) The molding equipment of the rare earth aluminum carbon silicon brake disc adopts a vacuum unit to provide vacuum conditions for a smelting chamber and a casting chamber; a smelting power supply is adopted to provide current for a heating induction coil in a smelting chamber, so that heat is provided for a crucible to heat materials, and meanwhile, a lifting temperature measuring component is matched to ensure that the crucible is heated to the smelting temperature; starting a heating component in the casting chamber to heat until the temperature of the forming mold reaches the pouring temperature, and linking the forming mold with a lifting mechanism to enter the melting chamber by opening a flap valve to pour the melt rare earth aluminum carbon silicon composite material in the crucible into the forming mold; and then the lifting mechanism is linked with the forming die to return to the casting chamber for forming to obtain the rare earth aluminum carbon silicon brake disc. The molding equipment is simple to operate, and can realize batch production of the rare earth aluminum carbon silicon brake disc.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
fig. 1 is a schematic structural diagram of a molding apparatus used in a method for molding a brake disc made of rare earth aluminum carbon silicon in embodiment 1 of the present invention;
FIG. 2 is a structural diagram of a metallographic structure of a rare earth Al-C-Si brake disc prepared in example 1 of the present invention;
the device comprises a smelting chamber 1, a casting chamber 2, a casting chamber 3, a vacuum unit 4, a smelting power supply 5, a flap valve 6, a first feeding mechanism 7, a second feeding mechanism 8, a third feeding mechanism 9, a crucible 10, a lifting temperature measuring component 11, a heating induction coil 12, a stirring mechanism 13, a forming die 14, a sand box 15, a lifting mechanism 16 and a heating component.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments that can be derived by one of ordinary skill in the art from the embodiments given herein are intended to be within the scope of the present invention.
Example 1:
a molding method of a rare earth aluminum carbon silicon brake disc comprises the following steps:
step S1, preparing modified silicon carbide powder
Adding a rare earth magnesium compound used for coating the surface of the alpha silicon carbide into the alpha silicon carbide, and carrying out activation treatment after the alpha silicon carbide is coated to prepare modified silicon carbide powder;
step S2, preparing rare earth aluminum silicon magnesium alloy
Mixing an aluminum alloy ingot and a synergist, and smelting under a vacuum condition to obtain a melt rare earth aluminum silicon magnesium alloy, wherein the rare earth aluminum silicon magnesium alloy comprises the following chemical components in percentage by mass: 6.5 to 7.5 percent of Si, 0.6 to 0.7 percent of Mg, 0.1 to 0.2 percent of Ti, 0.04 to 0.07 percent of Be, less than 0.5 percent of Re and the balance of Al;
s3, preparing the rare earth aluminum carbon silicon brake disc
Firstly, adding the modified silicon carbide powder into the melt rare earth aluminum silicon magnesium alloy prepared in the step S2, wherein the mass ratio of the modified silicon carbide powder to the rare earth aluminum silicon magnesium alloy is 1:3, and stirring and refining under a vacuum condition to prepare a melt rare earth aluminum carbon silicon composite material;
secondly, the rare earth aluminum silicon magnesium alloy is poured into a forming die 13 under the vacuum condition, and the rare earth aluminum carbon silicon brake disc is formed under the vacuum condition and the pouring temperature.
In step S1, the activation treatment includes drying and high-temperature baking treatment of the coated α -silicon carbide;
and after the activation treatment, the prepared modified silicon carbide powder is cooled, subjected to dust collection, screened, detected and packaged.
The particle size of the modified silicon carbide powder particles prepared in step S1 is 5-100 μm.
And S3, post-treatment is further included, wherein the post-treatment comprises the steps of sequentially carrying out demoulding, heat treatment, processing detection and warehousing treatment on the molded rare earth aluminum carbon silicon brake disc.
In step S3, the stirring speed was 500rpm, the refining temperature was 600 ℃ and the pouring temperature was 700 ℃.
In steps S2 to S3, the vacuum condition is 6Pa.
Referring to fig. 1, the molding equipment adopted by the molding method of the rare earth aluminum carbon silicon brake disc comprises a smelting chamber 1, a casting chamber 2, a vacuum unit 3 and a smelting power supply 4, wherein the smelting chamber 1 and the casting chamber 2 are connected through a flap valve 5, and the smelting chamber 1 and the casting chamber 2 are respectively connected with the vacuum unit 3 through vacuum pipelines; the smelting power supply 4 is connected with the smelting chamber 1;
a first feeding mechanism 6 for feeding aluminum alloy ingots into the smelting chamber 1, a second feeding mechanism 7 for feeding synergists into the smelting chamber 1 and a third feeding mechanism 8 for feeding modified silicon carbide powder into the smelting chamber 1 are arranged on the smelting chamber 1;
a crucible 9 and a lifting temperature measuring component 10 are arranged in the smelting chamber 1, and a heating induction coil 11 connected with a smelting power supply 4 is arranged on the outer surface of the crucible 9; the crucible 9 is respectively connected with the first feeding mechanism 6, the second feeding mechanism 7 and the third feeding mechanism 8 through vacuum valves; the lifting temperature measuring component 10 automatically lifts to be far away from the crucible 9 or enter the crucible 9 and is connected with the smelting power supply 4;
a stirring mechanism 12 is arranged on the smelting chamber 1, and the stirring end of the stirring mechanism 12 is arranged in the crucible 9;
a forming mould 13, a sand box 14 and a lifting mechanism 15 are arranged in the casting chamber 2, the sand box 14 is arranged on the lifting mechanism 15, and the forming mould 13 is arranged on the sand box 14 and corresponds to the flap valve 5; the forming mold 13 is provided with a first temperature thermocouple, the inner wall of the casting chamber 2 is provided with a heating member 16 (specifically, a heating resistance wire), and the heating member 16 is connected with the first temperature thermocouple and used for heating the forming mold 13 to a casting temperature.
The third feeding mechanism 8 comprises a charging barrel, a screw feeding part and an isolation ball valve for connecting the charging barrel and the screw feeding part;
a vibration component (specifically comprising a vibration motor and a pneumatic hammer) is arranged in the charging barrel and is used for feeding the modified silicon carbide powder into the screw feeding component in a vibration state;
the screw feeding component comprises a feeding pipe and a feeding screw arranged in the feeding pipe, and the feeding pipe is connected with the charging barrel through an isolation ball valve; and a heater for heating the feeding pipe and a second temperature thermocouple connected with the heater are arranged on the outer wall of the feeding pipe.
The stirring mechanism 12 is provided with a dustproof component, the stirring end of the stirring mechanism 12 is provided with a flow sensor, and the flow sensor is connected with a motor in the stirring mechanism 12 to ensure that the stirring shearing force meets the requirement.
The forming method of the rare earth aluminum carbon silicon brake disc adopts the forming equipment and has the following specific application process:
firstly, a vacuum unit 3 is adopted to provide vacuum conditions for a smelting chamber 1 and a casting chamber 2;
secondly, aluminum alloy ingots are put into a crucible 9 in the smelting chamber 1 through a first feeding mechanism 6, a smelting power supply 4 is used for supplying current to a heating induction coil 11 in the smelting chamber 1, heat is supplied to the crucible 9 to heat the aluminum alloy ingots, and meanwhile, a lifting temperature measuring component 10 is matched to ensure that the crucible 9 is heated to the smelting temperature;
then, adding a synergist into a crucible 9 in the smelting chamber 1 through a second feeding mechanism 7, after the synergist is mixed with an aluminum alloy ingot, smelting under a vacuum condition to prepare a melt rare earth aluminum silicon magnesium alloy, adding modified silicon carbide powder into the crucible 9 in the smelting chamber 1 through a third feeding mechanism 8 to prepare the melt rare earth aluminum silicon magnesium alloy, and stirring and refining under the vacuum condition to prepare a melt rare earth aluminum carbon silicon composite material;
finally, starting a heating component 16 in the casting chamber 2 to heat until the temperature of the forming mold 13 reaches the pouring temperature, and adopting a lifting mechanism 15 to link the forming mold 13 to enter the melting chamber 1 by opening a flap valve 5 to pour the melt rare earth aluminum carbon silicon composite material in the crucible 9 into the forming mold 13; and then the lifting mechanism 15 is linked with the forming die 13 to return to the casting chamber 2 for forming to obtain the rare earth aluminum carbon silicon brake disc (the metallographic structure of the rare earth aluminum carbon silicon brake disc is shown in figure 2).
The invention adopts the application process to manufacture the rare earth aluminum carbon silicon brake disc in batches.
The mechanical properties of the rare earth aluminum carbon silicon brake disc prepared by the invention after T5 treatment are shown in Table 1.
The mechanical properties of the rare earth aluminum carbon silicon brake disc prepared by the invention after annealing treatment are shown in table 2.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A molding method of a rare earth aluminum carbon silicon brake disc is characterized by comprising the following steps:
step S1, preparing modified silicon carbide powder
Adding a rare earth magnesium compound used for coating the surface of the alpha silicon carbide into the alpha silicon carbide, and carrying out activation treatment after the alpha silicon carbide is coated to prepare modified silicon carbide powder;
step S2, preparing rare earth aluminum silicon magnesium alloy
Mixing an aluminum alloy ingot and a synergist, and smelting under a vacuum condition to obtain a melt rare earth aluminum silicon magnesium alloy, wherein the rare earth aluminum silicon magnesium alloy comprises the following chemical components in percentage by mass: 6.5 to 7.5 percent of Si, 0.6 to 0.7 percent of Mg, 0.1 to 0.2 percent of Ti, 0.04 to 0.07 percent of Be, less than 0.5 percent of Re and the balance of Al;
s3, preparing the rare earth aluminum carbon silicon brake disc
Firstly, adding the modified silicon carbide powder into the melt rare earth aluminum silicon magnesium alloy prepared in the step S2, wherein the mass ratio of the modified silicon carbide powder to the rare earth aluminum silicon magnesium alloy is not higher than 1:3, and stirring and refining the mixture under a vacuum condition to prepare a melt rare earth aluminum carbon silicon composite material;
and secondly, pouring the rare earth aluminum silicon magnesium alloy into a forming die (13) under the vacuum condition, and forming under the vacuum condition and the pouring temperature to obtain the rare earth aluminum carbon silicon brake disc.
2. The method for molding the brake disc of claim 1, wherein in step S1, the activation treatment comprises drying and high-temperature baking the coated α -silicon carbide;
and after the activation treatment, the prepared modified silicon carbide powder is cooled, subjected to dust collection, screened, detected and packaged.
3. The method for molding a brake disc of rare earth aluminum carbon silicon as claimed in claim 2, wherein the particle size of the modified silicon carbide powder particles prepared in step S1 is 5-100 μm.
4. The method for molding the rare earth aluminum carbon silicon brake disc as claimed in claim 1, wherein the step S3 further comprises a post-treatment, and the post-treatment comprises sequentially carrying out demolding, heat treatment, processing detection and warehousing treatment on the molded rare earth aluminum carbon silicon brake disc.
5. The method of claim 1, wherein in step S3, the stirring speed is not less than 500rpm, the refining temperature is 560 to 610 ℃, and the casting temperature is 680 to 710 ℃.
6. The method for forming a brake disc of rare earth aluminum carbon silicon as claimed in claim 1, wherein the vacuum conditions used in steps S2-S3 are all air pressure less than 10Pa.
7. A forming device used in the forming method of the brake disc made of rare earth aluminum carbon silicon as claimed in any one of claims 1 to 6, characterized by comprising a smelting chamber (1), a casting chamber (2), a vacuum unit (3) and a smelting power supply (4), wherein the smelting chamber (1) and the casting chamber (2) are connected through a flap valve (5) and are respectively connected with the vacuum unit (3) through vacuum pipelines; the smelting power supply (4) is connected with the smelting chamber (1);
a first feeding mechanism (6) for feeding aluminum alloy ingots into the smelting chamber (1), a second feeding mechanism (7) for feeding a synergist into the smelting chamber (1) and a third feeding mechanism (8) for feeding modified silicon carbide powder into the smelting chamber (1) are arranged on the smelting chamber (1);
a crucible (9) and a lifting temperature measuring component (10) are arranged in the smelting chamber (1), and a heating induction coil (11) connected with a smelting power supply (4) is arranged on the outer surface of the crucible (9); the crucible (9) is respectively connected with the first feeding mechanism (6), the second feeding mechanism (7) and the third feeding mechanism (8) through vacuum valves; the lifting temperature measuring component (10) automatically lifts to be far away from the crucible (9) or enter the crucible (9), and is connected with the smelting power supply (4);
a stirring mechanism (12) is arranged on the smelting chamber (1), and the stirring end of the stirring mechanism (12) is arranged in the crucible (9).
8. The molding apparatus according to claim 7, wherein a molding die (13), a flask (14), and a lift mechanism (15) are provided in the molding chamber (2), the flask (14) is provided on the lift mechanism (15), and the molding die (13) is provided on the flask (14) and is provided in correspondence with the flap valve (5); the forming die (13) is provided with a first temperature thermocouple, the inner wall of the casting chamber (2) is provided with a heating part (16), and the heating part (16) is connected with the first temperature thermocouple and used for heating the forming die (13) to the pouring temperature.
9. The molding apparatus as defined in claim 8, wherein the third feeding mechanism (8) comprises a barrel, a screw feeding part and an isolation ball valve for connecting the two;
a vibrating component is arranged in the charging barrel and is used for feeding the modified silicon carbide powder into the screw feeding component in a vibrating state;
the screw feeding component comprises a feeding pipe and a feeding screw arranged in the feeding pipe, and the feeding pipe is connected with the charging barrel through an isolation ball valve; and a heater for heating the feeding pipe and a second temperature thermocouple connected with the heater are arranged on the outer wall of the feeding pipe.
10. The molding apparatus as defined in claim 9, wherein a dust-proof member is provided on the stirring mechanism (12), and a flow sensor is provided at a stirring end of the stirring mechanism (12), the flow sensor being connected to a motor in the stirring mechanism (12).
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Cited By (2)
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| CN116272502A (en) * | 2023-03-09 | 2023-06-23 | 广州易购智能设备股份有限公司 | Refining process and equipment for high-temperature refining composite brake disc of silicon-carbon material |
| CN117287966A (en) * | 2023-11-27 | 2023-12-26 | 四川威纳尔特种电子材料有限公司 | Smelting device and method for efficiently forming and producing blank pup joint for bonding wire |
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