CN117088691A - 复合材料刹车片的成型工艺 - Google Patents

复合材料刹车片的成型工艺 Download PDF

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CN117088691A
CN117088691A CN202311059151.XA CN202311059151A CN117088691A CN 117088691 A CN117088691 A CN 117088691A CN 202311059151 A CN202311059151 A CN 202311059151A CN 117088691 A CN117088691 A CN 117088691A
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powder
forming
brake pad
ceramic powder
mixing
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洪湛
刘伟善
洪彪俊
左晓东
傅文锋
戴理光
洪科杰
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Zhejiang Wansai Automobile Parts Co ltd
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Abstract

本发明公开了复合材料刹车片的成型工艺，本方案中重新设计陶瓷粉、胶黏剂等的配方，其中通过HfC粉体、SiCN、SiB6烧结形成的粉体配合胶黏剂等形成外致密层、内多孔疏松的层级，与胞体内外致密、内松的分布配合，多种层级分布构型有助提高韧性，以硅、硼强化配合第二相硬质颗粒的引入配合纤维强化等再度提高韧性。

Description

复合材料刹车片的成型工艺
技术领域
本发明涉及刹车片成型技术领域，具体涉及复合材料刹车片的成型工艺。
背景技术
在汽车的刹车系统中，刹车片为关键的零部件，近年来出于对环境、人体健康的考虑，含重金属等的刹车片逐步被摒弃，对此复合材料的刹车片成为研发热点，如陶瓷刹车片等，缺陷在于陶瓷材质存在脆性大、韧性差的缺陷，影响在刹车片领域的应用。
对于陶瓷材料韧性的改进多样化，如授权公告号为CN115160004B的专利文件中提出挤出制备陶瓷纤维胞体，并附着分隔层，之后排布并烧结成型的方案，缺陷在于其断裂韧性不能满足本司的应用需求，需改进。
发明内容
为解决上述至少一个技术缺陷，本发明提供了如下技术方案：
本申请文件公开复合材料刹车片的成型工艺，包括以下步骤：
第一、将纳米陶瓷粉、胶黏剂一、水按照质量比80-90:2-3:100形成的陶瓷浆料以挤制的方法形成陶瓷纤维胞体，以质量计，其中纳米陶瓷粉为7-8:5的碳化硅与氧化铝组成，以20-26：35-42：5-8：4-6：10-13:4-6:0.2-0.4：4-6的比例将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、钛酸钾晶须、不锈钢纤维、蛭石、苯并噁嗪树脂、锌粉混合形成胶黏剂一；
第二、按照量比80-90:2-3:22-25：100将微米陶瓷粉、胶黏剂二、聚乙二醇、水相混形成浆料，将陶瓷纤维胞体浸入该浆料中并干燥，以质量计，将HfC粉体、SiCN、SiB6按照量比70-80：2-3：4-4.5混合并烧结形成微米陶瓷粉，以质量计将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、莫来石纤维按照40-50:35-45:1-3：10-13的量比混合形成胶黏剂二；
第三、坯体成型、排胶及烧结成型。
本方案中重新设计陶瓷粉、胶黏剂等的配方，其中通过HfC粉体、SiCN、SiB6烧结形成的粉体配合胶黏剂等形成外致密层、内多孔疏松的层级，与胞体内外致密、内松的分布配合，多种层级分布构型有助提高韧性，以硅、硼强化配合第二相硬质颗粒的引入配合纤维强化等再度提高韧性。
进一步，将HfC粉体、SiCN、SiB6按照量比混合进行球磨，并烘干备用，之后将烘干后的粉体进行SPS烧结。
进一步，SPS烧结时首先以90-110℃/min的速度升温至1100℃，之后以60-75℃/min的速度升温至1800℃，同步加压至50±2MPa，保压20±3min，自然降至室温并粉碎至微米级，即微米陶瓷粉。在上述工艺参数下有助形成所需结构的材料，进而增强刹车片的韧性。
进一步，纳米陶瓷粉的尺寸为0.2-5μm，微米陶瓷粉尺寸为2-6μm，陶瓷纤维胞体的尺寸为800-1000μm，优选尺寸参数，有助提高刹车片性能。
进一步，坯体成型：将第二步干燥后的陶瓷纤维胞体定向排布并加压成型，保压脱模后得到坯体。
进一步，排胶：将所得坯体在520-600℃氮气环境下保温排胶，之后在480-540℃下保温去除剩下的碳化物；烧结成型：将排胶后的坯体以等离子烧结方式烧结15-25min，压力40-50MPa，冷却脱模。
与现有技术相比，本发明的有益效果：
1、本发明重新设计胞体及界面层的物料组成，相配合下形成多层级的外密、内松构型，配合第二向SiC的引入等，刹车片的韧性提升明显。
具体实施方式
下面结合具体实施例对本发明作进一步说明。
实施例1
复合材料刹车片的成型工艺，包括以下步骤：
第一、将纳米陶瓷粉、胶黏剂一、水按照质量比80:2:100混合搅拌均匀形成陶瓷浆料，将陶瓷浆料以挤制的方法形成陶瓷纤维胞体，胞体的直径在900±50μm。
以质量计，其中纳米陶瓷粉为7:5的碳化硅粉体、氧化铝颗粒组成。
以20：35：5：4：10:4:0.2：4的质量比例将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、钛酸钾晶须、不锈钢纤维、蛭石、苯并噁嗪树脂、锌粉混合并搅拌均匀形成胶黏剂一。
第二、按照量比80:2:22：100将微米陶瓷粉、胶黏剂二、聚乙二醇4000、水相混形成浆料，将陶瓷纤维胞体浸入该浆料中并干燥，干燥后胞体外附着厚度约30-40μm。
以质量计，将HfC粉体、SiCN、SiB6按照量比70：2：4混合进行球磨，加入异丙醇为介质，球磨混合均匀后，在60℃烘箱干燥备用。将干燥后的粉体进行SPS烧结，SPS烧结时首先以90℃/min的速度升温至1100℃，之后以60℃/min的速度升温至1800℃，同步加压至50MPa，保压20min，自然降至室温并粉碎至微米级2-6μm，即微米陶瓷粉。
以质量计将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、莫来石纤维按照40:35:1：10的量比混合形成胶黏剂二。
第三、坯体成型，将第二步中所得的胞体在钢模具中按一维定向排布，之后在220MPa下加压成型，保压10min脱模后得到坯体。
第四、将第三步所得的坯体在580℃氮气环境下，保温排胶，之后在480℃下空气条件下保温去除剩下的碳化物，等离子烧结15min，压力45MPa，温度1180±20℃，自然冷却后脱模即可。
实施例2
复合材料刹车片的成型工艺，包括以下步骤：
第一、将纳米陶瓷粉、胶黏剂一、水按照质量比85:2.5:100混合搅拌均匀形成陶瓷浆料，将陶瓷浆料以挤制的方法形成陶瓷纤维胞体，胞体的直径在900±50μm。
以质量计，其中纳米陶瓷粉为7.5:5的碳化硅粉体、氧化铝颗粒组成。
以23：38：6：4.6：11:4.7:0.3：5的质量比例将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、钛酸钾晶须、不锈钢纤维、蛭石、苯并噁嗪树脂、锌粉混合并搅拌均匀形成胶黏剂一。
第二、按照量比85:2.3:24：100将微米陶瓷粉、胶黏剂二、聚乙二醇3000、水相混形成浆料，将陶瓷纤维胞体浸入该浆料中并干燥，干燥后胞体外附着厚度约30-40μm。
以质量计，将HfC粉体、SiCN、SiB6按照量比74：2.3：4.2混合进行球磨，加入异丙醇为介质，球磨混合均匀后，在60℃烘箱干燥备用。将干燥后的粉体进行SPS烧结，SPS烧结时首先以100℃/min的速度升温至1100℃，之后以65℃/min的速度升温至1800℃，同步加压至50MPa，保压20min，自然降至室温并粉碎至微米级2-6μm，即微米陶瓷粉。
以质量计将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、莫来石纤维按照45:40:1.5：12的量比混合形成胶黏剂二。
第三、坯体成型，将第二步中所得的胞体在钢模具中按一维定向排布，之后在220MPa下加压成型，保压10min脱模后得到坯体。
第四、将第三步所得的坯体在580℃氮气环境下，保温排胶，之后在500℃下空气条件下保温去除剩下的碳化物，等离子烧结15min，压力45MPa，温度1180±20℃，自然冷却后脱模即可。
实施例3
复合材料刹车片的成型工艺，包括以下步骤：
第一、将纳米陶瓷粉、胶黏剂一、水按照质量比88:2.7:100混合搅拌均匀形成陶瓷浆料，将陶瓷浆料以挤制的方法形成陶瓷纤维胞体，胞体的直径在900±50μm。
以质量计，其中纳米陶瓷粉为7.8:5的碳化硅粉体、氧化铝颗粒组成。
以25：40：7：5.2：5:12:0.3：5.2的质量比例将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、钛酸钾晶须、不锈钢纤维、蛭石、苯并噁嗪树脂、锌粉混合并搅拌均匀形成胶黏剂一。
第二、按照量比87:2.7:24：100将微米陶瓷粉、胶黏剂二、聚乙二醇4000、水相混形成浆料，将陶瓷纤维胞体浸入该浆料中并干燥，干燥后胞体外附着厚度约30-40μm。
以质量计，将HfC粉体、SiCN、SiB6按照量比78：2.7：4.4混合进行球磨，加入异丙醇为介质，球磨混合均匀后，在60℃烘箱干燥备用。将干燥后的粉体进行SPS烧结，SPS烧结时首先以95℃/min的速度升温至1100℃，之后以70℃/min的速度升温至1800℃，同步加压至50MPa，保压20min，自然降至室温并粉碎至微米级2-6μm，即微米陶瓷粉。
以质量计将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、莫来石纤维按照48:42:2：12的量比混合形成胶黏剂二。
第三、坯体成型，将第二步中所得的胞体在钢模具中按一维定向排布，之后在220MPa下加压成型，保压10min脱模后得到坯体。
第四、将第三步所得的坯体在580℃氮气环境下，保温排胶，之后在480℃下空气条件下保温去除剩下的碳化物，等离子烧结15min，压力45MPa，温度1180±20℃，自然冷却后脱模即可。
实施例4
复合材料刹车片的成型工艺，包括以下步骤：
第一、将纳米陶瓷粉、胶黏剂一、水按照质量比90:3:100混合搅拌均匀形成陶瓷浆料，将陶瓷浆料以挤制的方法形成陶瓷纤维胞体，胞体的直径在900±50μm。
以质量计，其中纳米陶瓷粉为8:5的碳化硅粉体、氧化铝颗粒组成。
以26：42：8：6：13:6:0.4：6的质量比例将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、钛酸钾晶须、不锈钢纤维、蛭石、苯并噁嗪树脂、锌粉混合并搅拌均匀形成胶黏剂一。
第二、按照量比90:3:25：100将微米陶瓷粉、胶黏剂二、聚乙二醇4000、水相混形成浆料，将陶瓷纤维胞体浸入该浆料中并干燥，干燥后胞体外附着厚度约30-40μm。
以质量计，将HfC粉体、SiCN、SiB6按照量比80：3：4.5混合进行球磨，加入异丙醇为介质，球磨混合均匀后，在60℃烘箱干燥备用。将干燥后的粉体进行SPS烧结，SPS烧结时首先以90℃/min的速度升温至1100℃，之后以60℃/min的速度升温至1800℃，同步加压至50MPa，保压20min，自然降至室温并粉碎至微米级2-6μm，即微米陶瓷粉。
以质量计将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、莫来石纤维按照50:45:3：13的量比混合形成胶黏剂二。
第三、坯体成型，将第二步中所得的胞体在钢模具中按一维定向排布，之后在220MPa下加压成型，保压10min脱模后得到坯体。
第四、将第三步所得的坯体在580℃氮气环境下，保温排胶，之后在480℃下空气条件下保温去除剩下的碳化物，等离子烧结15min，压力45MPa，温度1180±20℃，自然冷却后脱模即可。
对比例1
与实施例4的区别在于：微米陶瓷粉中无SiB6，以等质量的SiCN替换SiB6。
对比例2
与实施例4的区别在于：微米陶瓷粉中无SiCN，以等质量的SiB6替换SiCN。
将上述制备的刹车片进行性能的测试，如表1所示。
表1
断裂韧性(MPa.m1/2)
实施例1 10.7
实施例2 10.2
实施例3 10.6
实施例4 10.5
对比例1 8.3
对比例2 8.1
可以看出，本方案成型的刹车片在限定组分配比及工艺下得到的刹车片在断裂韧性上增加明显，对于其他耐磨、摩擦系数、耐热性等均能满足刹车片的性能指标需求。
以上仅是本发明的优选实施方式，本发明的保护范围并不仅局限于上述实施例，凡属于本发明思路下的技术方案均属于本发明的保护范围。应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理前提下的若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (6)

1.复合材料刹车片的成型工艺，其特征在于，包括以下步骤：
第一、将纳米陶瓷粉、胶黏剂一、水按照质量比80-90:2-3:100形成的陶瓷浆料以挤制的方法形成陶瓷纤维胞体，以质量计，其中纳米陶瓷粉为7-8:5的碳化硅与氧化铝组成，以20-26：35-42：5-8：4-6：10-13:4-6:0.2-0.4：4-6的比例将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、钛酸钾晶须、不锈钢纤维、蛭石、苯并噁嗪树脂、锌粉混合形成胶黏剂一；
第二、按照量比80-90:2-3:22-25：100将微米陶瓷粉、胶黏剂二、聚乙二醇、水相混形成浆料，将陶瓷纤维胞体浸入该浆料中并干燥，以质量计，将HfC粉体、SiCN、SiB6按照量比70-80：2-3：4-4.5混合并烧结形成微米陶瓷粉，以质量计将硼酚醛树脂、聚乙烯醇、硫酸钙晶须、莫来石纤维按照40-50:35-45:1-3：10-13的量比混合形成胶黏剂二；
第三、坯体成型、排胶及烧结成型。
2.如权利要求1所述的复合材料刹车片的成型工艺，其特征在于：将HfC粉体、SiCN、SiB6按照量比混合进行球磨，并烘干备用，之后将烘干后的粉体进行SPS烧结。
3.如权利要求2所述的复合材料刹车片的成型工艺，其特征在于：SPS烧结时首先以90-110℃/min的速度升温至1100℃，之后以60-75℃/min的速度升温至1800℃，同步加压至50±2MPa，保压20±3min，自然降至室温并粉碎至微米级，即微米陶瓷粉。
4.如权利要求1所述的复合材料刹车片的成型工艺，其特征在于：纳米陶瓷粉的尺寸为0.2-5μm，微米陶瓷粉尺寸为2-6μm，陶瓷纤维胞体的尺寸为800-1000μm。
5.如权利要求1所述的复合材料刹车片的成型工艺，其特征在于：坯体成型：将第二步干燥后的陶瓷纤维胞体定向排布并加压成型，保压脱模后得到坯体。
6.如权利要求1所述的复合材料刹车片的成型工艺，其特征在于：排胶：将所得坯体在520-600℃氮气环境下保温排胶，之后在480-540℃下保温去除剩下的碳化物；烧结成型：将排胶后的坯体以等离子烧结方式烧结15-25min，压力40-50MPa，冷却脱模。
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117623747A (zh) * 2023-12-12 2024-03-01 新化县群华陶瓷科技有限公司 一种98氧化铝陶瓷材料及制备工艺

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