CN116690125B - 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 PDF

Info

Publication number
CN116690125B
CN116690125B CN202310938421.8A CN202310938421A CN116690125B CN 116690125 B CN116690125 B CN 116690125B CN 202310938421 A CN202310938421 A CN 202310938421A CN 116690125 B CN116690125 B CN 116690125B
Authority
CN
China
Prior art keywords
aluminum
based composite
stirring
brake disc
composite material
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.)
Active
Application number
CN202310938421.8A
Other languages
Chinese (zh)
Other versions
CN116690125A (en
Inventor
朱正锋
谭东
张士琦
陆荣
付康习
夏少华
李娄明
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CRRC Qishuyan Institute Co Ltd
Original Assignee
CRRC Qishuyan Institute Co Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by CRRC Qishuyan Institute Co Ltd filed Critical CRRC Qishuyan Institute Co Ltd
Priority to CN202310938421.8A priority Critical patent/CN116690125B/en
Publication of CN116690125A publication Critical patent/CN116690125A/en
Application granted granted Critical
Publication of CN116690125B publication Critical patent/CN116690125B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/02Braking members; Mounting thereof
    • F16D65/12Discs; Drums for disc brakes
    • F16D65/125Discs; Drums for disc brakes characterised by the material used for the disc body
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00Materials; Production methods therefor
    • F16D2200/0004Materials; Production methods therefor metallic
    • F16D2200/0026Non-ferro
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00Materials; Production methods therefor
    • F16D2200/0082Production methods therefor
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/20Recycling

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

Preparation method of aluminum-based composite brake disc and brake disc
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,
arctanφ-1< β <arctan2φ-2,
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.
Description of the embodiments
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:
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.
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
arctanφ-1< β <arctan2φ-2
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 (9)

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 a shaft shoulder D2 and an 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 matched 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; wherein the shaft shoulder D2 and the inclination angle beta of the needleless repairing stirring head simultaneously meet the following requirements,
1.5φ<D2<2φ-2,
arctanφ-1< β <arctan2φ-2,
wherein phi is the maximum size of the casting defect, and phi is more than 5mm and less than 25mm.
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: 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.
4. 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.
5. The method for manufacturing an aluminum-based composite brake disc according to claim 4, wherein: the reinforcing particles are silicon carbide powder.
6. The method for manufacturing an aluminum-based composite brake disc according to claim 4, wherein: the reinforced particles need to be screened and placed into an oven for roasting pretreatment before being added into a solution.
7. 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.
8. 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.
9. 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 8.
CN202310938421.8A 2023-07-28 2023-07-28 Preparation method of aluminum-based composite brake disc and brake disc Active CN116690125B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202310938421.8A CN116690125B (en) 2023-07-28 2023-07-28 Preparation method of aluminum-based composite brake disc and brake disc

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202310938421.8A CN116690125B (en) 2023-07-28 2023-07-28 Preparation method of aluminum-based composite brake disc and brake disc

Publications (2)

Publication Number Publication Date
CN116690125A CN116690125A (en) 2023-09-05
CN116690125B true CN116690125B (en) 2023-10-03

Family

ID=87829563

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202310938421.8A Active CN116690125B (en) 2023-07-28 2023-07-28 Preparation method of aluminum-based composite brake disc and brake disc

Country Status (1)

Country Link
CN (1) CN116690125B (en)

Citations (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2000015426A (en) * 1998-07-08 2000-01-18 Daido Steel Co Ltd Repair/improvement method for defect/defect in structure inside metal member
JP2000042781A (en) * 1998-07-29 2000-02-15 Showa Alum Corp Method for repairing recessed defect part
CN1968783A (en) * 2004-03-24 2007-05-23 Sii米加钻石公司 Solid state processing of materials through friction stir processing and friction stir mixing
CN101530947A (en) * 2009-04-08 2009-09-16 西安交通大学 Method for preparing bimetal composite plate by stirring friction braze welding
US8052029B1 (en) * 2010-09-01 2011-11-08 GM Global Technology Operations LLC Method of calibrating a friction stir spot welding system
CN102500915A (en) * 2011-11-08 2012-06-20 西安交通大学 Method for filling friction stir welding keyhole by using T-shaped filling block and bitless stirring head
KR101282659B1 (en) * 2012-05-02 2013-07-12 울산대학교 산학협력단 Fabrication method of metal matrix composite joints by friction stir spot welding(fssw)
CN106624342A (en) * 2017-01-23 2017-05-10 沈阳航空航天大学 Method for repairing metal component volumetric defect through stirring friction welding
CN106670642A (en) * 2017-01-23 2017-05-17 沈阳航空航天大学 Friction-stir welding tool and method of repairing key hole defect by using friction-stir welding tool
CN108127244A (en) * 2017-12-20 2018-06-08 北京万洲汇联科技有限公司 A kind of dissimilar material mispairing handles two pass friction stir welding method
CN108788504A (en) * 2018-07-05 2018-11-13 南京中车浦镇城轨车辆有限责任公司 A kind of restorative procedure of large scale agitating friction weldering weld defect
CN110977138A (en) * 2019-11-15 2020-04-10 唐山宏正机械设备有限公司 Aluminum alloy double-shaft-shoulder friction stir welding defect repairing method
CN111687594A (en) * 2020-05-31 2020-09-22 西安交通大学 Friction stir welding repair method for large-area damage of engine disk
CN112143921A (en) * 2020-09-23 2020-12-29 中车戚墅堰机车车辆工艺研究所有限公司 Preparation method for preparing aluminum matrix composite brake disc
CN113618330A (en) * 2021-07-20 2021-11-09 南京航空航天大学 Repair device and method for repairing titanium alloy and steel structure through aluminum alloy solid-phase material increase
CN114789297A (en) * 2022-05-31 2022-07-26 沈阳航空航天大学 Friction stir welding repair method for thin-wall heterogeneous metal layered composite material
CN114932304A (en) * 2022-04-28 2022-08-23 国营四达机械制造公司 Friction stir welding repairing method for part hole side wall chipping defect
CN116348234A (en) * 2020-09-23 2023-06-27 中车戚墅堰机车车辆工艺研究所有限公司 Composite brake disc, preparation method thereof and friction stir tool
CN116352249A (en) * 2023-04-23 2023-06-30 吉林大学 Method for preparing metal matrix composite by friction stir processing and application

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR102460557B1 (en) * 2018-02-02 2022-10-28 가부시키가이샤 후루야긴조쿠 Repair/modification method of metal-based substrates

Patent Citations (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2000015426A (en) * 1998-07-08 2000-01-18 Daido Steel Co Ltd Repair/improvement method for defect/defect in structure inside metal member
JP2000042781A (en) * 1998-07-29 2000-02-15 Showa Alum Corp Method for repairing recessed defect part
CN1968783A (en) * 2004-03-24 2007-05-23 Sii米加钻石公司 Solid state processing of materials through friction stir processing and friction stir mixing
CN101530947A (en) * 2009-04-08 2009-09-16 西安交通大学 Method for preparing bimetal composite plate by stirring friction braze welding
US8052029B1 (en) * 2010-09-01 2011-11-08 GM Global Technology Operations LLC Method of calibrating a friction stir spot welding system
CN102500915A (en) * 2011-11-08 2012-06-20 西安交通大学 Method for filling friction stir welding keyhole by using T-shaped filling block and bitless stirring head
KR101282659B1 (en) * 2012-05-02 2013-07-12 울산대학교 산학협력단 Fabrication method of metal matrix composite joints by friction stir spot welding(fssw)
CN106670642A (en) * 2017-01-23 2017-05-17 沈阳航空航天大学 Friction-stir welding tool and method of repairing key hole defect by using friction-stir welding tool
CN106624342A (en) * 2017-01-23 2017-05-10 沈阳航空航天大学 Method for repairing metal component volumetric defect through stirring friction welding
CN108127244A (en) * 2017-12-20 2018-06-08 北京万洲汇联科技有限公司 A kind of dissimilar material mispairing handles two pass friction stir welding method
CN108788504A (en) * 2018-07-05 2018-11-13 南京中车浦镇城轨车辆有限责任公司 A kind of restorative procedure of large scale agitating friction weldering weld defect
CN110977138A (en) * 2019-11-15 2020-04-10 唐山宏正机械设备有限公司 Aluminum alloy double-shaft-shoulder friction stir welding defect repairing method
CN111687594A (en) * 2020-05-31 2020-09-22 西安交通大学 Friction stir welding repair method for large-area damage of engine disk
CN112143921A (en) * 2020-09-23 2020-12-29 中车戚墅堰机车车辆工艺研究所有限公司 Preparation method for preparing aluminum matrix composite brake disc
CN116348234A (en) * 2020-09-23 2023-06-27 中车戚墅堰机车车辆工艺研究所有限公司 Composite brake disc, preparation method thereof and friction stir tool
CN113618330A (en) * 2021-07-20 2021-11-09 南京航空航天大学 Repair device and method for repairing titanium alloy and steel structure through aluminum alloy solid-phase material increase
CN114932304A (en) * 2022-04-28 2022-08-23 国营四达机械制造公司 Friction stir welding repairing method for part hole side wall chipping defect
CN114789297A (en) * 2022-05-31 2022-07-26 沈阳航空航天大学 Friction stir welding repair method for thin-wall heterogeneous metal layered composite material
CN116352249A (en) * 2023-04-23 2023-06-30 吉林大学 Method for preparing metal matrix composite by friction stir processing and application

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
夏宁 ; 吴惠惠 ; 李东风 ; 刘晨 ; 吉华 ; 徐红勇 ; .搅拌摩擦焊接接头表面犁沟缺陷修复工艺研究.机车车辆工艺.2020,(第01期),41-43. *
张铁浩 ; 刘雪松 ; 邢艳双 ; .搅拌摩擦焊修复ZL210铸造铝合金组织与性能分析.焊接学报.2018,(第04期),118-121. *

Also Published As

Publication number Publication date
CN116690125A (en) 2023-09-05

Similar Documents

Publication Publication Date Title
US20230349435A1 (en) Composite brake disc, preparation method thereof and friction stir tool
CN108486431B (en) Al-Si-Mg series aluminum alloy composition for selective laser melting technology and preparation method of formed part
CN112143921B (en) Preparation method for preparing aluminum matrix composite brake disc
CN112413012B (en) Composite brake disc
CN105568036B (en) Preparing method of high-silicon aluminum composite material
CN105525153A (en) Brake disc prepared from silicon carbide particle reinforced aluminum matrix composite material
CN107043882B (en) A kind of preparation method of diamond composite
CN103240402B (en) A kind of production method of particle enhanced aluminum-based composite material ingot casting
CN110744058A (en) Preparation method for in-situ synthesis of copper-based composite material
CN116200632B (en) High-strength and high-toughness die-casting aluminum alloy, and preparation method and application thereof
JPWO2015141191A1 (en) Compressor impeller made of Al alloy casting and manufacturing method thereof
CN116690125B (en) Preparation method of aluminum-based composite brake disc and brake disc
CN111500905A (en) High-silicon aluminum alloy modified based on selective laser melting nano ceramic
CN110157950B (en) Reduced graphene oxide reinforced zinc-based medical material and preparation method thereof
CN101446243B (en) Piston made of Al/Si-Mg*Si composite material and preparation method thereof
CN1278802C (en) Process for extrusion casting piston blank of internal combustion engine with local feinforcing of metal base composite material
CN113423853A (en) Aluminum alloy for structural high pressure vacuum die casting applications
Gong et al. Non-keyhole friction stir welding for 6061-T6 aluminum alloy
CN110343895B (en) In situ TiB2Preparation method of particle-reinforced AlCu-based composite material
Purohit et al. Fabrication of a cam using metal matrix composites
CN112974842A (en) Nano multiphase reinforced aluminum matrix composite material and preparation method thereof
US20110150694A1 (en) METHOD FOR MANUFACTURING Ti PARTICLE-DISPERSED MAGNESIUM-BASED COMPOSITE MATERIAL
Zou et al. Influence of SiC content on microstructure and mechanical properties of SiCp/AlSi7Mg composites fabricated by selective laser melting
CN107475551A (en) The method that mechanical mixing method prepares aluminum matrix composite
Vijayavel et al. Effect of tool traverse speed on strength, hardness, and ductility of friction-stir-processed LM25AA-5% SiCp metal matrix composites

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
GR01 Patent grant
GR01 Patent grant
CP03 Change of name, title or address
CP03 Change of name, title or address

Address after: 213000, No. 258, Wuyi Road, Changzhou City, Jiangsu Province

Patentee after: CRRC Qishuyan Locomotive and Rolling Stock Technology Research Institute Co.,Ltd.

Address before: 213000, No. 258, Wuyi Road, Changzhou City, Jiangsu Province

Patentee before: CRRC QISHUYAN INSTITUTE Co.,Ltd.