CN116690125A - Preparation method of aluminum-based composite brake disc and brake disc - Google Patents
Preparation method of aluminum-based composite brake disc and brake disc Download PDFInfo
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- CN116690125A CN116690125A CN202310938421.8A CN202310938421A CN116690125A CN 116690125 A CN116690125 A CN 116690125A CN 202310938421 A CN202310938421 A CN 202310938421A CN 116690125 A CN116690125 A CN 116690125A
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- aluminum
- based composite
- stirring
- brake disc
- composite material
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 150
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 150
- 239000002131 composite material Substances 0.000 title claims abstract description 135
- 238000002360 preparation method Methods 0.000 title claims abstract description 38
- 238000003756 stirring Methods 0.000 claims abstract description 167
- 230000007547 defect Effects 0.000 claims abstract description 106
- 238000005266 casting Methods 0.000 claims abstract description 55
- 238000000034 method Methods 0.000 claims abstract description 41
- 239000000945 filler Substances 0.000 claims abstract description 28
- 238000011049 filling Methods 0.000 claims abstract description 28
- 230000008569 process Effects 0.000 claims abstract description 28
- 239000011159 matrix material Substances 0.000 claims abstract description 23
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 10
- 230000008439 repair process Effects 0.000 claims description 36
- 239000002245 particle Substances 0.000 claims description 31
- 238000004519 manufacturing process Methods 0.000 claims description 18
- 239000000463 material Substances 0.000 claims description 14
- 239000000155 melt Substances 0.000 claims description 14
- 230000003014 reinforcing effect Effects 0.000 claims description 11
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 9
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 8
- 239000007788 liquid Substances 0.000 claims description 8
- 238000000465 moulding Methods 0.000 claims description 8
- 238000012545 processing Methods 0.000 claims description 8
- 238000007670 refining Methods 0.000 claims description 8
- 238000004140 cleaning Methods 0.000 claims description 6
- 238000007872 degassing Methods 0.000 claims description 6
- 239000003607 modifier Substances 0.000 claims description 6
- 238000005303 weighing Methods 0.000 claims description 6
- 239000003795 chemical substances by application Substances 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- 229910052786 argon Inorganic materials 0.000 claims description 4
- 238000005275 alloying Methods 0.000 claims description 3
- 238000007664 blowing Methods 0.000 claims description 3
- 238000007873 sieving Methods 0.000 claims description 3
- 230000003044 adaptive effect Effects 0.000 claims description 2
- 239000007789 gas Substances 0.000 claims description 2
- 238000011156 evaluation Methods 0.000 claims 1
- 239000010410 layer Substances 0.000 description 26
- 239000011246 composite particle Substances 0.000 description 8
- 230000000694 effects Effects 0.000 description 7
- 230000000052 comparative effect Effects 0.000 description 6
- 230000009471 action Effects 0.000 description 5
- -1 aluminum-silicon-copper Chemical compound 0.000 description 5
- 230000009467 reduction Effects 0.000 description 4
- 230000002787 reinforcement Effects 0.000 description 4
- 229910000676 Si alloy Inorganic materials 0.000 description 3
- 229910001278 Sr alloy Inorganic materials 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 3
- YNDGDLJDSBUSEI-UHFFFAOYSA-N aluminum strontium Chemical compound [Al].[Sr] YNDGDLJDSBUSEI-UHFFFAOYSA-N 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 238000005253 cladding Methods 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 238000004134 energy conservation Methods 0.000 description 3
- 239000012535 impurity Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- 230000007704 transition Effects 0.000 description 3
- 229910000881 Cu alloy Inorganic materials 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 238000005265 energy consumption Methods 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 239000006173 Good's buffer Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 210000001787 dendrite Anatomy 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
- F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0004—Materials; Production methods therefor metallic
- F16D2200/0026—Non-ferro
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0082—Production methods therefor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Abstract
The invention discloses a preparation method of an aluminum-based composite material brake disc and the brake disc, comprising the steps of preparing an aluminum alloy matrix, an aluminum-based composite material plate and an aluminum-based composite filler; and (3) grading the cast air hole defects of the aluminum-based composite material plate, determining the effective filling property of friction stir forming, directly performing friction stir forming by adopting a stirring head with a stirring pin when the defect size is smaller than or equal to the diameter D1 of the stirring pin to prepare the aluminum-based composite material brake disc, filling the cast air hole defects of the aluminum-based composite material plate with the aluminum-based composite filler when the defect size is larger than the diameter D1 of the stirring pin, performing friction stir repairing on the cast air hole defects by adopting a needleless repairing stirring head, and performing friction stir forming after repairing is completed to prepare the aluminum-based composite material brake disc. The method can timely fill casting defects of the aluminum-based composite material plate, improves friction stir quality, ensures quality stability in the friction stir process, and reduces preparation difficulty and cost of the plate.
Description
Technical Field
The invention relates to the technical field of brake disc manufacturing, in particular to a preparation method of an aluminum-based composite brake disc and the brake disc.
Background
Under the background that energy conservation and emission reduction and environmental pollution reduction become basic national policies, the weight of rail transit vehicles is reduced, and energy consumption and emission generated by frequent starting and braking are reduced, so that the method is one of the most effective methods for realizing energy conservation and emission reduction. The novel light material brake disc is used for replacing the traditional steel and iron material brake disc so as to lighten the weight of unsprung parts of the running vehicle, maintain the ideal unsprung weight ratio and be the most effective way for realizing energy conservation and emission reduction.
The aluminum-based ceramic composite material has the advantages of short production period, low manufacturing cost and low density, and can obviously reduce the unsprung weight of a train and reduce the traction power loss when being applied to the preparation of a brake disc. The Chinese patent with the publication number of CN112143921B is a prior application filed by the applicant, and provides a preparation method for preparing an aluminum-based composite brake disc. The friction surface of the brake disc is coated with the aluminum-based composite material in a friction stir forming mode, so that the weight of the brake disc can be reduced, the surface friction layer of the brake disc is made of the aluminum-based composite material, the matrix layer is made of common cast aluminum, and the brake disc has good mechanical property and forming manufacturability while good friction and wear performance is ensured.
The brake disc has the advantages of improving the extensibility, reducing the failure risk, increasing the thermal diffusion coefficient, transmitting out the heat generated by the friction layer, reducing the temperature rise and having excellent overall performance while improving the wear resistance. However, the aluminum-based composite material has the defects of poor molding manufacturability, easiness in forming air holes in the production and manufacturing process, and the like. Although the friction stir can fill the material in the stirring area, the material in one area is essentially used for filling the material in the other area, so that the defects such as larger pores and gaps cannot be filled, and the defects such as furrows are easily generated in the parts which cannot be filled, thereby influencing the friction stir quality. If the air hole composite board with larger defects is scrapped, the efficiency, the yield and the cost of the product preparation are directly affected. If the defects such as the air holes are eliminated, a large amount of equipment is required to improve the plate forming process, but the production cost of the product is obviously increased. In addition, for the aluminum-based composite material with high alloy or high ceramic particle content, due to poor material fluidity in the friction stir process, the defects such as furrows and the like are easy to generate, and the generation of the defects can influence the friction stir quality, so that the product is scrapped.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a preparation method of an aluminum-based composite material brake disc and the brake disc, which can timely fill casting defects of aluminum-based composite material plates, such as air holes and the like, ensure sufficient gap materials in the friction stir process, improve the friction stir quality, ensure the quality stability in the friction stir process, and reduce the preparation difficulty and cost of the plates.
The technical scheme for realizing the purpose of the invention is as follows:
the preparation method of the aluminum-based composite brake disc comprises the following steps:
step S1: preparing an aluminum alloy matrix and an aluminum-based composite material plate, processing according to the outline size of the disc surface of the brake disc, and collecting aluminum-based composite material residues obtained by cutting the aluminum-based composite material plate;
step S2: crushing and sieving the collected aluminum-based composite material residues to form aluminum-based composite filler;
step S3: and (5) grading the air hole casting defects of the aluminum-based composite material plate, and judging whether the air hole casting defects have repairability. Measuring the air hole defect through a vernier caliper, and judging that the defect can be directly used for preparing the aluminum-based composite material brake disc by adopting the stirring pin to directly stir friction forming when the defect size phi is smaller than or equal to the diameter D1 of the stirring pin without repairing; when the defect size phi is larger than the diameter D1 of the stirring pin, judging that stirring repair is needed;
step S4: marking and recording a defect area with the size larger than D1, cleaning the air hole defect simply by an air pump blowing mode before repairing, and filling the aluminum-based composite filler into the marked air hole defect area of the aluminum-based composite material plate after cleaning is completed, wherein the filling depth of the aluminum-based composite filler is higher than the depth of the casting defect to be repaired;
step S5: after filling, determining the shaft shoulder D2 and the inclination angle beta of the needleless repairing stirring head according to the recorded maximum casting defect size so as to ensure that the casting defect can be effectively coated for high-quality stirring repairing, simultaneously determining the adaptive stirring friction forming repairing process parameters for stirring friction repairing the casting defect, checking after repairing, and adopting the stirring head with a stirring needle for stirring friction forming to prepare the aluminum-based composite material brake disc from qualified products.
Further, the shoulder D2 and the inclination angle beta of the needleless repair stirring head in the step S4 simultaneously meet the following requirements,
1.5φ<D2<2φ-2,
arctan2φ-2< β <arctanφ-1,
wherein phi is the maximum size of the casting defect, and phi is more than 5mm and less than 25mm.
Further, the filling height of the aluminum-based composite filler is required to be more than 2mm above the surface of the aluminum-based composite board.
Further, the technological parameters of the needleless repairing stirring head for repairing casting defects by friction stir forming are 1000-2000 r/min, and the pressing amount is 0.05-0.5 mm.
Further, the preparation of the aluminum-based composite material plate comprises the following steps,
step S11: weighing an aluminum ingot, weighing an alterant and a refiner according to the weight ratio of the aluminum ingot, and putting the aluminum ingot, the alterant and the refiner into a baking oven for baking;
step S12: heating an aluminum ingot to 750 ℃ in a vacuum environment to completely melt the aluminum liquid, adding alloying materials, modifier, refining agent and refiner, and introducing argon gas into the aluminum liquid for degassing and refining;
step S13: mechanically stirring the melt, adding reinforcing particles into the melt at a constant speed while stirring, and stirring and homogenizing;
step S14: and controlling the temperature of the melt at 700-720 ℃, and casting under the vacuum condition to prepare the aluminum-based composite material plate.
Further, the reinforcing particles are silicon carbide powder.
Further, the reinforcing particles need to be screened and placed in an oven for roasting pretreatment before being added into a solution.
Further, the particle size of the aluminum-based composite filler is smaller than 1mm.
Further, in the step S5, a stirring head with a stirring pin is adopted for stirring friction molding, and stirring friction molding technological parameters of preparing the aluminum-based composite brake disc are 600-1200 r/min in rotation speed and 100-300 mm/min in feeding speed.
By adopting the technical scheme, the invention has the following beneficial effects:
according to the invention, after the casting defects in the aluminum-based composite material plate are rated in a grading manner, whether friction stir repair is needed or not is judged according to the size of the casting defects, and a specific repair method is provided, namely, the casting air hole defects of the aluminum-based composite material plate can be filled in due time by taking the cutting excess materials as aluminum-based composite filler to fill the casting defects after being processed in the process of preparing the aluminum-based composite material plate, so that the sufficiency of gap materials in the friction stir process is ensured, the stability in the friction stir preparation process is ensured, the friction stir quality is improved, and the preparation difficulty and cost of the plate are reduced. And meanwhile, the needleless repair stirring head repairs the composite material plate in a solid-phase friction welding mode, the melting and solidification of the metal material do not occur, the residual stress is low, the deformation is small, the plate repair effect is good, the operation is more flexible, and the energy consumption and the cost are low.
The filling depth of the aluminum-based composite filler is higher than the depth of the casting defect to be repaired, so that the aluminum-based composite filler can be ensured to fully fill the cavity of the casting defect, and the aluminum-based composite filler has enough composite material flowing in the friction stir repairing process, thereby effectively repairing the casting defect.
The structural parameters of the needleless repairing stirring head used in the friction stir repairing, namely the shaft shoulder dimension D2 and the inclination angle beta, are limited, so that the structural parameters matched with the repairing defect dimension phi are determined, the needleless repairing stirring head is ensured to have excellent cladding property and heat input property in the friction stir repairing process, and a good friction stir repairing effect on casting defects is ensured.
According to the invention, by limiting the technological parameters of the needleless repairing stirring head, namely, setting the rotating speed and the pressing-in quantity of a larger section, the matched technological parameters can be selected aiming at defects with different sizes, and the optimal effect of friction stir repairing is ensured.
The preparation of the aluminum-based composite material plate improves the performance of the aluminum-based composite material plate by adding reinforcing particles and by three reinforcing mechanisms of particle bearing reinforcement, dislocation reinforcement and Orowan reinforcement.
The reinforced particles of the invention adopt silicon carbide powder, and have high mechanical strength, good rigidity, high hardness, abrasion resistance, high temperature resistance and low density, so that the brake disc is lighter.
In the preparation of the aluminum-based composite material plate, the reinforcing particles are subjected to roasting pretreatment to remove surface impurities and adsorb moisture, and meanwhile, a layer of oxide film is formed on the surfaces of the reinforcing particles, so that the contact wettability of the reinforcing particles and an aluminum matrix is improved, the performance of the aluminum-based composite material plate is improved, and the performance requirement of a brake disc is met.
The particle size of the aluminum-based composite filler is smaller than 1mm, and filler particles with small particle size can ensure that casting defects are fully filled, the inner filling is compact, the filler is not easy to be lost due to the action of shaft shoulder stirring external force, and the stirring friction repair quality is ensured.
The technological parameters of the friction stir forming process for preparing the aluminum-based composite brake disc are 600-1200 r/min, the feeding speed is 100-300 mm/min, the friction stir forming effect is good under the parameter interval, the internal metal can effectively flow, and the quality of the finished product of the aluminum-based composite brake disc is ensured.
Drawings
In order that the invention may be more readily understood, a more particular description of the invention will be rendered by reference to specific embodiments that are illustrated in the appended drawings, in which:
FIG. 1 is a flow chart of a preparation method of the present invention;
FIG. 2 is a schematic diagram of a stirring head with a stirring pin for stirring and preparing according to the invention;
FIG. 3 is a schematic illustration of the needleless repair stirring head of the present invention.
Detailed Description
In order to better understand the above technical solutions, the following detailed description will refer to the accompanying drawings and specific embodiments.
Example 1
The brake disc of the embodiment is manufactured by adopting the manufacturing method of the aluminum-based composite brake disc shown in fig. 1, wherein the manufacturing method comprises the following steps:
step S1: preparing an aluminum alloy matrix and an aluminum-based composite material plate, processing according to the outline dimension of the disc surface of the brake disc, collecting the aluminum-based composite material residue obtained by cutting the aluminum-based composite material plate, and keeping the aluminum-based composite material clean, wherein the preparation method of the aluminum alloy matrix and the aluminum-based composite material plate specifically comprises the following steps:
1. preparation of aluminum alloy matrix
And forming a brake disc blank by adopting an aluminum-silicon alloy or an aluminum-silicon-copper alloy as a matrix alloy through a casting molding process. Firstly, aluminum-silicon alloy or aluminum-silicon-copper alloy or aluminum-silicon alloy containing a small amount of ceramic particles is used as a matrix alloy to form an aluminum ingot, and an aluminum-strontium alloy modifier and an aluminum-titanium-boron refiner are weighed according to the weight of the aluminum ingot. Then, the aluminum ingot, the aluminum strontium alloy modifier and the aluminum titanium boron refiner are put into a baking oven for baking so as to remove the moisture. Heating the dried aluminum ingot to 700-800 ℃, adding an aluminum strontium alloy modifier, a refining agent and an aluminum titanium boron refining agent into the aluminum ingot when the aluminum ingot is completely melted, and simultaneously introducing argon into melted aluminum liquid for degassing treatment, wherein the degassing time is 30-50 minutes. The temperature of the aluminum liquid is controlled to be 700-720 ℃, a special brake disc metal mold is used, and the casting of the brake disc blank body is carried out by adopting low-pressure casting, wherein the casting process comprises liquid lifting, filling, crusting, pressure maintaining and pressure relief. And finally, opening the die, and taking out the aluminum alloy brake disc blank casting. And (5) performing primary processing on the substrate layer according to the outline size of the disc surface of the brake disc to obtain a brake disc blank.
2. Preparation of aluminum-based composite material plate
Step S11: weighing an aluminum ingot, weighing an alterant and a refiner according to the weight ratio of the aluminum ingot, and putting the aluminum ingot, the alterant and the refiner into a baking oven for baking so as to remove surface impurities and adsorb moisture;
step S12: heating an aluminum ingot to 750 ℃ in a vacuum environment to completely melt the aluminum liquid, adding alloying materials, modifier, refining agent and refiner, introducing argon into the aluminum liquid to degas and refine, and removing water vapor and impurities in the melt to effectively purify the melt, wherein the degassing and refining time is 15-30 minutes;
step S13: after degassing, mechanically stirring the melt, wherein the rotating speed of a motor is 500-600 r/min, and uniformly adding pretreated silicon carbide powder into the melt as reinforcing particles while stirring, so that the mechanical strength is high, the rigidity is good, the hardness is high, the wear resistance and the high temperature are high, and meanwhile, the density is low. The adding speed of the silicon carbide powder is 2-5 g/s, the rotating speed of the motor is adjusted to 800r/min after the silicon carbide powder is completely added, and the silicon carbide in the melt is stirred and homogenized;
step S14: when silicon carbide particles are fully dispersed and uniformly dispersed in a melt, controlling the temperature of the melt to be 700-720 ℃, and casting the melt into a composite material plate under the condition of vacuum, so as to prepare an aluminum-based composite material plate with silicon carbide particle reinforcement;
step S2: crushing and sieving the collected aluminum-based composite material residues, and screening out composite material particles with the particle size smaller than 1mm as aluminum-based composite filler;
step S3: and selecting a proper stirring head with a stirring pin according to the performance requirement and the quality requirement of the aluminum matrix composite brake disc, wherein the sizes h, D and t of the stirring head are the interface sizes of a handle of the stirring friction device, and the stirring head is processed according to the type of the device, and the diameter D1 of the stirring pin is related to the size of the brake disc to be stirred, and the conventional range is 5-15 mm. And (3) grading the casting defects in the aluminum matrix composite plate, measuring the air hole defects through a vernier caliper, and judging whether the air hole defects have repairability. When the defect size phi is smaller than or equal to the diameter D1 of the stirring pin, judging that the defect can be directly used for preparing the aluminum-based composite brake disc by directly adopting the stirring head with the stirring pin to stir friction molding without repairing; when the defect size phi is larger than the diameter D1 of the stirring pin, judging that stirring repair is needed;
step S4: marking and recording the defect area with the size larger than D1, and cleaning the air hole defect simply by blowing through an air pump before repairing. After cleaning, filling the aluminum-based composite filler into the marked air hole defect area of the aluminum-based composite material plate, wherein the filling depth of the aluminum-based composite filler is higher than the depth of the casting defect to be repaired;
step S5: after filling, the shaft shoulder D2 and the inclination angle beta of the needleless repairing stirring head are determined according to the recorded maximum casting defect size, so that the casting defect can be effectively coated and high-quality stirring repairing can be carried out. And simultaneously, determining the matched friction stir forming repair process parameters to repair the casting defects, checking after repair, and adopting a stirring pin to perform friction stir forming on qualified products to prepare the aluminum-based composite brake disc.
As shown in FIG. 3, the shoulder D2 and the inclination angle beta of the needleless repair stirring head simultaneously meet the following requirements
1.5φ<D2<2φ-2
arctan2φ-2< β <arctanφ-1
Wherein phi is the maximum size of the casting defect, and phi is more than 5mm and less than 25mm.
Filling the aluminum-based composite filler into the defect cavity of the aluminum-based composite material plate to be repaired, and filling the defect cavity to be higher than the surface of the plate by more than 2 mm; according to the casting defect size, a matched needleless repairing stirring head is selected according to the size requirement, and because the defect size is larger than the diameter D1 of a stirring needle, filler filled into the defect can be directly thrown away to cause repairing failure when stirring friction repairing is carried out, the needleless repairing stirring head with the structure is adopted, corresponding stirring parameters are set, the rotating speed of the stirring head is 1000-2000 r/min, the pressing amount is 0.05-0.5 mm, and stirring friction repairing is carried out. In the repairing process, the needleless stirring head presses the aluminum-based composite filler into the aluminum-based composite material plate under the condition of high-speed rotation, filling particles can be guaranteed to be always under the coating of the shaft shoulder under the action of a certain inclination angle of the shaft shoulder, meanwhile, the plate is subjected to high-speed rotation friction heating of the shaft shoulder to achieve a plasticizing state, the plasticized metal material flows fully under the extrusion of a stirring tool and the upsetting force of the shaft shoulder, and after the atomic diffusion and the reconstruction process of a metal bond are carried out, the plate defect is filled fully, so that the stirring friction preparation requirement is met. Because the chemical components of the aluminum-based composite filler and the aluminum-based composite material plate are consistent, the newly added granular material has good combination with the original composite material in the stirring friction process, and the performance of the composite layer is not affected.
And after the repair is finished, adopting a stirring head with a stirring pin to stir and rub and mold to prepare the aluminum-based composite brake disc.
The process flow of friction stir forming is as follows:
the aluminum alloy substrate is fixed on a workbench of a friction stir test, aluminum-based composite material plates which are not required to be repaired or repaired are stacked on a friction plane of the plate body, and the aluminum plate and the aluminum-based composite material plates are fixed through a tool, so that the assembly stability of the aluminum-based composite material plates is ensured, and the friction stir forming preparation process is not influenced.
And (3) carrying out friction stir forming preparation on the surface of the aluminum-based composite material plate, wherein the stirring rotation speed is 600-1200 r/min, and the feeding speed is 100-300 mm/min. The stirring head is utilized to rotate at a high speed to heat the surface of the aluminum alloy matrix to a plastic state, the aluminum-based composite material plate and the aluminum alloy matrix are effectively connected under the action of the stirring pin in a friction stir welding nuclear area, the aluminum-based composite material plate on the upper layer is modified, and a composite layer of the aluminum-based composite material brake disc is formed after cooling. At the bottom edge of the stirring pin, the matrix material and the aluminum-based composite material cannot be effectively mixed, original dendrites in the matrix are smashed and redistributed, crystal grain refinement is formed, and a transition layer of the aluminum-based composite material brake disc is formed after cooling.
After friction stir processing, the aluminum-based composite material layer and the matrix layer are completely integrated, and a blank body of the aluminum-based composite material brake disc is formed after cooling.
And (3) processing and removing the blank seam on the surface of the composite layer to finish the processing of the datum plane of the aluminum-based composite material brake disc. And (5) taking the aluminum-based composite material layer as a reference to finish the processing of the aluminum-based composite material brake disc. The brake disc is divided into three layers, the surface layer is an aluminum-based composite layer, the brake disc has the characteristics of high hardness and good wear resistance, the bottom is a matrix layer, the brake disc has a bearing function, good mechanical property and impact resistance are achieved, a transition layer is arranged between the matrix layer and the composite layer, a small amount of SIC particles are arranged between the matrix layer and the composite layer, eutectic silicon is scattered, and the wear resistance and the mechanical property are between the matrix layer and the composite layer. Because the matrix layer and the composite layer have different linear expansion coefficients, the intermediate transition layer has good buffer effect and good cold and hot fatigue resistance.
According to the embodiment, after the casting defects inside the aluminum-based composite material plate are rated in a grading manner, whether friction stir repair is needed or not is judged according to the size of the casting defects, and a specific repair method is provided, namely, the casting defects of the aluminum-based composite material plate, such as air holes and the like, can be timely filled by taking the cutting excess materials obtained in the preparation of the aluminum-based composite material plate as aluminum-based composite filler to fill the casting defects, so that the sufficient gap materials in the friction stir process are ensured, the friction stir quality is improved, the quality stability in the friction stir process is ensured, and the preparation difficulty and cost of the plate are reduced.
Comparative example 1
The process of this example is similar to example 1 except that the shoulder D2 of the needleless repair stirring head is less than 1.5 phi. In this example, the maximum defect size was 15mm, and the needleless repair stirring head shoulder size D2 was 20mm, β=86°. In the process of repairing the casting defects, because the friction radius of the shaft shoulder is too small, effective coating of the composite particles filled in the defect area is difficult to realize, a large amount of filling particles are stirred out under the action of high-speed rotation of the stirring head, so that the height of the filling particles in the inner cavity of the casting defects is greatly reduced, and finally, only partial areas of the casting defects are subjected to the stirring friction repairing action, and the macroscopic characterization is that the repaired defects are of a concave structure.
Comparative example 2
The preparation method of this example is similar to example 1, except that the shoulder D2 of the needleless repair stirring head is greater than 2 phi-2. In this example, the maximum defect size was 15mm, and the needleless repair stirring head shoulder size D2 was 35mm, β=86°. Because the shaft shoulder is oversized, the coverage area is far beyond the casting defect area, and when the composite particle filler only fills the defect area to the surface layer of 2mm, the shaft shoulder is fully contacted with the surface of the plate, so that the repair area near the defect is not required to be contacted with the stirring repair shaft shoulder. In the process of repairing casting defects, the areas are also subjected to upsetting force exerted by the stirring shaft shoulders downwards, so that after the repairing process is finished, the areas are lowered to a certain extent compared with the planes of other areas of the plate, and in the process of preparing the brake disc by adopting friction stir forming, when the stirring head stirs to the areas, the shaft shoulders are difficult to contact with the surface planes of the repaired areas, so that insufficient friction heat generation is caused, and further the product quality is influenced. If the situation that the repairing area near the defect does not need to be pressed down after repairing is required to be ensured, more composite particles need to be filled until the contact area of the stirring shaft shoulder and the plate is full of the filled composite particles, and the number of the filled composite particles is increased, so that the preparation cost is further increased.
Comparative example 3
The preparation method of this example is similar to example 1, except that the tilt angle β of the needleless repair stirring head satisfies β < arctanD2/2. In this example, the maximum defect size was 10mm, and the needleless repair stirring head shoulder size D2 was 17mm, β=82°. In the process of repairing casting defects, the inclination angle beta of the needleless repairing stirring head is too small, the concave degree of the shaft shoulder of the stirring head is too large, the shaft shoulder is too deep into the matrix, abnormal pressing-in phenomenon is generated, the effective thickness of the repaired composite board is reduced, meanwhile, the deformation of the product is influenced to a certain extent, and finally the product quality is reduced.
Comparative example 4
The preparation of this example is similar to example 1, except that the bevel angle β of the needleless repair stirring head satisfies β > arctanD2. In this example, the maximum defect size was 10mm, the needleless repair stirring head shoulder size D2 was 17mm, and β=90°. In the process of repairing casting defects, the inclination angle beta of the needleless repairing stirring head is too large, the inward concave degree of the shaft shoulder of the stirring head is too small, the coating property of filling composite particles into a defect area is weak in the process of rotating friction of the shaft shoulder, and the filling particles continuously overflow in the process of stirring and rotating, so that the repairing degree of the defects is weak, and the subsequent aluminum disc stirring friction molding preparation process is easily influenced.
Comparative example 5
The preparation method of this example is similar to example 1, except that the needleless repair stirring head differs in that the shoulder D2 of the needleless repair stirring head is greater than 2 phi-2, beta < arctan phi-1. In this example, the maximum defect size was 15mm, and the needleless repair stirring head shoulder size D2 was 35mm, β=80°. In the process of repairing casting defects, under the common influence of high concave degree of a large shaft shoulder and a stirring head shaft shoulder, the repaired defect area is subjected to a large amount of heat input, so that the phenomena of black spots and the like on the surface of the plate after the defects are repaired, and the quality of the plate is influenced. Meanwhile, as the coverage area of the large shaft shoulder is wider, the effective thickness of the plate is greatly thinned under the structure with high indent degree, and finally the friction stir preparation quality is affected.
Comparative example 6
The preparation method of this example is similar to example 1, except that the needleless prosthetic stirring head differs in that the shoulder D2 of the needleless prosthetic stirring head is less than 1.5 phi and beta > arctan2 phi-2. In this example, the maximum defect size was 15mm, and the needleless repair stirring head shoulder size D2 was 20mm, β=90°. In this embodiment, because the shoulder friction radius is too little, be difficult to realize effective cladding to defect region filling composite particle, simultaneously because the inclination beta of stirring head is too big, stirring head shoulder indent degree is little, further weakens to defect filling composite particle's cladding nature, under dual effect, a large amount of filling particles are stirred out, lead to casting defect inner chamber filling particle height to reduce by a wide margin, finally lead to casting defect only to receive friction stir repair effect in partial region, the overall repair effect is not good, influence product quality.
While the foregoing is directed to embodiments of the present invention, other and further details of the invention may be had by the present invention, it should be understood that the foregoing description is merely illustrative of the present invention and that no limitations are intended to the scope of the invention, except insofar as modifications, equivalents, improvements or modifications are within the spirit and principles of the invention.
Claims (10)
1. The preparation method of the aluminum-based composite brake disc is characterized by comprising the following steps of:
step S1: preparing an aluminum alloy matrix and an aluminum-based composite material plate, processing according to the outline size of the disc surface of the brake disc, and collecting aluminum-based composite material residues obtained by cutting the aluminum-based composite material plate;
step S2: crushing and sieving the collected aluminum-based composite material residues to form aluminum-based composite filler;
step S3: determining a matched stirring preparation stirring head according to the disc type number of the to-be-stirred preparation; carrying out grading evaluation on the air hole casting defects of the aluminum-based composite material plate, and judging whether the air hole casting defects have repairability; measuring the air hole defect, and judging that the defect can be directly subjected to friction stir forming through the stirring pin to prepare the aluminum-based composite brake disc without repairing when the defect size phi is smaller than or equal to the diameter D1 of the stirring pin; when the defect size phi is larger than the diameter D1 of the stirring pin, judging that stirring repair is needed;
step S4: marking and recording a defect area with the size larger than D1, cleaning the air hole defect simply by an air pump blowing mode before repairing, and filling the aluminum-based composite filler into the marked air hole defect area of the aluminum-based composite material plate after cleaning is completed, wherein the filling depth of the aluminum-based composite filler is higher than the depth of the casting defect to be repaired;
step S5: after filling, determining the shaft shoulder D2 and the inclination angle beta of the needleless repairing stirring head according to the recorded maximum casting defect size so as to ensure that the casting defect can be effectively coated for high-quality stirring repairing, simultaneously determining the adaptive stirring friction forming repairing process parameters for stirring friction repairing the casting defect, checking after repairing, and adopting the stirring head with a stirring needle for stirring friction forming to prepare the aluminum-based composite material brake disc from qualified products.
2. The method for manufacturing an aluminum-based composite brake disc according to claim 1, wherein: the filling height of the aluminum-based composite filler is required to be more than 2mm above the surface of the aluminum-based composite board.
3. The method for manufacturing an aluminum-based composite brake disc according to claim 1, wherein: the shoulder D2 and the inclination angle beta of the needleless repair stirring head in the step S4 simultaneously meet the following requirements,
1.5φ<D2<2φ-2,
arctan2φ-2< β <arctanφ-1,
wherein phi is the maximum size of the casting defect, and phi is more than 5mm and less than 25mm.
4. The method for manufacturing an aluminum-based composite brake disc according to claim 1, wherein: and step S5, the friction stir forming repair process parameters are that the rotating speed is 1000-2000 r/min, and the pressing-in amount is 0.05-0.5 mm.
5. The method for manufacturing an aluminum-based composite brake disc according to claim 1, wherein: the preparation of the aluminum-based composite material plate comprises the following steps:
step S11: weighing an aluminum ingot, weighing an alterant and a refiner according to the weight ratio of the aluminum ingot, and putting the aluminum ingot, the alterant and the refiner into a baking oven for baking;
step S12: heating an aluminum ingot to be completely melted in a vacuum environment, adding an alloying material, a modifier, a refining agent and a refiner, and introducing argon gas into the aluminum liquid for degassing and refining;
step S13: mechanically stirring the melt, adding reinforcing particles into the melt at a constant speed while stirring, and stirring and homogenizing;
step S14: and controlling the temperature of the melt at 700-720 ℃, and casting under the vacuum condition to prepare the aluminum-based composite material plate.
6. The method for manufacturing an aluminum-based composite brake disc according to claim 5, wherein: the reinforcing particles are silicon carbide powder.
7. The method for manufacturing an aluminum-based composite brake disc according to claim 5, wherein: the reinforced particles need to be screened and placed into an oven for roasting pretreatment before being added into a solution.
8. The method for manufacturing an aluminum-based composite brake disc according to claim 1, wherein: the particle size of the aluminum-based composite filler is smaller than 1mm.
9. The method for manufacturing an aluminum-based composite brake disc according to claim 1, wherein: in the step S5, a stirring head with a stirring pin is adopted for stirring friction molding, and the technological parameters of the stirring friction molding preparation are that the rotating speed is 600-1200 r/min and the feeding speed is 100-300 mm/min.
10. A brake disc, characterized in that: a brake disc manufactured by the manufacturing method of the aluminum-based composite material according to any one of claims 1 to 9.
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