CN117962432A - High-strength high-toughness carbon ceramic brake disc and preparation method thereof - Google Patents
High-strength high-toughness carbon ceramic brake disc and preparation method thereof Download PDFInfo
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- CN117962432A CN117962432A CN202311810225.9A CN202311810225A CN117962432A CN 117962432 A CN117962432 A CN 117962432A CN 202311810225 A CN202311810225 A CN 202311810225A CN 117962432 A CN117962432 A CN 117962432A
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims abstract description 66
- 229910052799 carbon Inorganic materials 0.000 title claims abstract description 66
- 239000000919 ceramic Substances 0.000 title claims abstract description 57
- 238000002360 preparation method Methods 0.000 title description 8
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 221
- 239000004917 carbon fiber Substances 0.000 claims abstract description 221
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 191
- 239000004744 fabric Substances 0.000 claims abstract description 49
- 238000005475 siliconizing Methods 0.000 claims description 33
- 229910052582 BN Inorganic materials 0.000 claims description 26
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 26
- 238000007731 hot pressing Methods 0.000 claims description 18
- 238000005229 chemical vapour deposition Methods 0.000 claims description 17
- 238000000151 deposition Methods 0.000 claims description 16
- 230000008021 deposition Effects 0.000 claims description 16
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 15
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 14
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 14
- 238000000034 method Methods 0.000 claims description 11
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 9
- 238000010000 carbonizing Methods 0.000 claims description 9
- 238000001035 drying Methods 0.000 claims description 9
- 238000003754 machining Methods 0.000 claims description 9
- 239000005011 phenolic resin Substances 0.000 claims description 9
- 229920001568 phenolic resin Polymers 0.000 claims description 9
- 238000005498 polishing Methods 0.000 claims description 9
- 238000004321 preservation Methods 0.000 claims description 9
- 239000011863 silicon-based powder Substances 0.000 claims description 9
- 238000003763 carbonization Methods 0.000 claims description 8
- 229910052757 nitrogen Inorganic materials 0.000 claims description 7
- 238000005470 impregnation Methods 0.000 claims description 5
- 229910052710 silicon Inorganic materials 0.000 claims description 5
- 239000010703 silicon Substances 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 3
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- 230000000052 comparative effect Effects 0.000 description 5
- 238000009423 ventilation Methods 0.000 description 5
- 239000000835 fiber Substances 0.000 description 4
- 229910001018 Cast iron Inorganic materials 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 239000002783 friction material Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- CREMABGTGYGIQB-UHFFFAOYSA-N carbon carbon Chemical compound C.C CREMABGTGYGIQB-UHFFFAOYSA-N 0.000 description 1
- 239000011203 carbon fibre reinforced carbon Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005087 graphitization Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
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Abstract
The invention provides a high-strength high-toughness carbon ceramic brake disc, which comprises N carbon fiber unidirectional cloth layers and N chopped carbon fiber layers, wherein the carbon fiber unidirectional cloth layers and the chopped carbon fiber layers are stacked in a staggered manner, the thickness of the carbon fiber unidirectional cloth layers is 0.4-0.8mm, and the thickness of the chopped carbon fiber layers is 0.5-1mm. Through optimizing brake disc blank structure, set up carbon fiber unidirectional cloth layer and chopped carbon fiber layer in turn, compare ordinary carbon fiber unidirectional cloth and net child's combination mode, can further improve the bulk strength and the toughness of brake disc.
Description
Technical Field
The invention relates to the technical field of brake disc manufacturing, in particular to a high-strength high-toughness carbon ceramic brake disc and a preparation method thereof.
Background
Brake materials for modern vehicles such as airplanes, automobiles, and high-speed trains have undergone development from cast iron, synthetic materials, powder metallurgy materials to carbon-carbon composite materials and carbon-ceramic composite materials. In fact, they perform more strongly than cast iron brake discs, both carbon and carbon-ceramic brake discs. With the rapid development of the transportation industry, the vehicle braking performance requirement is also improved, the area of the friction material is smaller and smaller, the energy born by the friction material in unit area is higher and higher requirements on the strength and toughness of the brake disc are also provided.
At present, the carbon ceramic brake disc is mostly combined in a mode of unidirectional cloth and net tyre in the preparation process, a carbon fiber blank is obtained through a multilayer needling process, and then the carbon ceramic brake disc is obtained through high-temperature treatment, chemical vapor deposition, high-temperature treatment and siliconizing process. The web layers exist between the continuous fibers, and the fibers in the web layers exist mostly as individual fibers, and even after chemical vapor deposition, the carbon fibers are easily corroded by silicon, resulting in lower sample strength. Therefore, the strength of the whole brake disc cannot be integrally and effectively improved, and the high-strength high-toughness carbon ceramic brake disc is provided, so that the high-performance requirement of the existing brake disc is met.
Disclosure of Invention
The invention aims to provide a high-strength high-toughness carbon ceramic brake disc and a preparation method thereof, and the strength and toughness of the brake disc are improved by optimizing the matrix structure and the flow process of the brake disc.
In order to achieve the purpose, the invention provides a high-strength high-toughness carbon ceramic brake disc, which comprises N carbon fiber unidirectional cloth layers and N chopped carbon fiber layers, wherein N is a natural number larger than 1, the carbon fiber unidirectional cloth layers and the chopped carbon fiber layers are stacked in a staggered manner, the thickness of the carbon fiber unidirectional cloth layers is 0.4-0.8mm, and the thickness of the chopped carbon fiber layers is 0.5-1mm.
Preferably, the carbon fiber unidirectional cloth layer comprises a plurality of unidirectional carbon fiber bundles, and the interval between two adjacent unidirectional carbon fiber bundles is 1-4mm.
Preferably, the unidirectional carbon fiber bundles are 4-12K carbon fiber bundles.
Preferably, the carbon fiber bundles of the chopped carbon fibers in the chopped carbon fiber layer are 2-8K.
Preferably, the length of the chopped carbon fibers in the chopped carbon fiber layer is 5-15mm.
Preferably, the chopped carbon fiber layer comprises chopped carbon fibers, the outer surface of the chopped carbon fibers is coated with a deposited carbon layer, and the thickness of the deposited carbon layer is 0.5-1.5 mu m.
Preferably, the high-strength high-toughness carbon ceramic brake disc comprises 40-55% of silicon carbide, 45-60% of carbon and 4-15% of silicon.
The invention also provides a preparation method of the high-strength high-toughness carbon ceramic brake disc, which comprises the following steps:
Step 1: performing chemical vapor deposition on the carbon fibers and cutting the deposited carbon fibers to a preset length;
step 2: taking a plurality of carbon fiber unidirectional cloths, and continuously overlapping the carbon fiber unidirectional cloths and a layer of chopped carbon fibers in a mold in a combined mode until a stacked carbon fiber body with a preset thickness is obtained;
step 3: carrying out impregnation treatment on the stacked carbon fiber body;
step 4: drying the impregnated stacked carbon fiber body;
step 5: carrying out hot pressing treatment on the dried stacked carbon fiber body, and removing a die after the hot pressing treatment to obtain a hot pressed carbon fiber blank;
Step 6: carbonizing the hot-pressed carbon fiber blank;
step 7: machining the hot-pressed carbon fiber blank to obtain a brake disc blank;
step 8: placing the brake disc blank into a boron nitride crucible and placing the boron nitride crucible into a high-temperature vacuum furnace for siliconizing treatment;
Step 9: and (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the carbon ceramic brake disc.
Preferably, in the step 1, the included angle of 90 degrees is formed between the carbon fiber directions of the upper and lower carbon fiber unidirectional cloths of each chopped carbon fiber layer.
Preferably, the chemical vapor deposition conditions in step 1 are: the flow rate of methane is 80-180L/h, the flow rate of nitrogen is 3-20L/h, the deposition temperature is 950-1100 ℃, and the deposition time is 80-200h.
Preferably, the impregnating solution in the step 3 is a phenolic resin alcohol solution with the weight percent of 30-50.
Preferably, in the step 5, the temperature of the hot press is 150 ℃, the pressure is 3-10MPa, and the hot pressing time is 4 hours.
Preferably, the carbonization temperature in step 6 is 1000 ℃.
Preferably, in the step 8, the boron nitride crucible is pre-placed with pure silicon powder with the mass 1.1 times of the brake disc blank.
Preferably, the siliconizing treatment temperature in the step 8 is 1600-1700 ℃, the heat preservation time is 2-4h, and the furnace pressure is less than 1000Pa.
The beneficial effects are that: according to the high-strength high-toughness carbon ceramic brake disc, the carbon fiber unidirectional cloth layers and the chopped carbon fiber layers are alternately arranged by optimizing the blank structure of the brake disc, so that the overall strength and toughness of the brake disc can be further improved compared with the common combination mode of the carbon fiber unidirectional cloth and the net tire. Because the chopped carbon fiber bundles contain a large number of carbon fiber yarns, the carbon fibers are not easy to be corroded by liquid silicon during siliconizing, and good strength and toughness are still maintained after siliconizing, so that the problems of low strength and poor toughness of the net tire layer after siliconizing can be effectively solved. And the carbon fibers in the chopped fiber layer of the carbon ceramic brake disc are subjected to chemical vapor deposition, so that the carbon fibers are better protected during siliconizing, and the problem of strength reduction caused by siliconizing is effectively avoided.
Drawings
FIG. 1 is a schematic diagram of the structure of the high-strength high-toughness carbon ceramic brake disc.
Fig. 2 is a schematic side view of a brake disc blank.
In the figure: 1-brake disc blank, 2-chopped carbon fiber layer, 3-carbon fiber unidirectional cloth layer.
Detailed Description
The embodiments described below are only some, but not all, embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The embodiment provides a high-strength high-toughness carbon ceramic brake disc, a brake disc blank of the high-strength high-toughness carbon ceramic brake disc comprises N carbon fiber unidirectional cloth layers and N chopped carbon fiber layers, the carbon fiber unidirectional cloth layers and the chopped carbon fiber layers are stacked in a staggered mode, the thickness of the carbon fiber unidirectional cloth layers is 0.4-0.8mm, and the thickness of the chopped carbon fiber layers is 0.5-1mm. N is a natural number of 1 or more.
Referring to fig. 1 and 2, the bottom of the brake disc blank 1 is a chopped carbon fiber layer 2, the upper layer of the chopped carbon fiber layer 2 is a carbon fiber unidirectional cloth layer 3, the upper layer of the carbon fiber unidirectional cloth layer 3 is a second chopped carbon fiber layer 2, the upper layer of the second chopped carbon fiber layer 2 is a second carbon fiber unidirectional cloth layer 3, and the two layers are sequentially overlapped in this way, and the top of the brake disc blank 1 is a chopped carbon fiber layer 2. The brake disc blank 1 is provided with 5 layers of chopped carbon fiber layers 2 and 4 layers of carbon fiber unidirectional cloth layers 3.
The carbon fiber unidirectional cloth layer comprises a plurality of unidirectional carbon fiber bundles, and the interval between two adjacent unidirectional carbon fiber bundles is 1-4mm.
The unidirectional carbon fiber bundles are 4-12K carbon fiber bundles.
The carbon fiber bundles of the chopped carbon fibers in the chopped carbon fiber layer are 2-8k.
The length of the chopped carbon fibers in the chopped carbon fiber layer is 5-15mm.
The outer surface of the chopped carbon fiber in the chopped carbon fiber layer is a deposited carbon layer, and the thickness of the deposited carbon layer is 0.5-1.5 mu m.
The high-strength high-toughness carbon ceramic brake disc comprises 40-55% of silicon carbide, 45-60% of carbon and 4-15% of silicon.
The preparation method of the high-strength high-toughness carbon ceramic brake disc comprises the following steps:
Step 1: performing chemical vapor deposition on the carbon fibers and cutting the deposited carbon fibers to a preset length;
step 2: taking a plurality of carbon fiber unidirectional cloths, and continuously overlapping the carbon fiber unidirectional cloths and a layer of chopped carbon fibers in a mold in a combined mode until a stacked carbon fiber body with a preset thickness is obtained;
step 3: carrying out impregnation treatment on the stacked carbon fiber body;
step 4: drying the impregnated stacked carbon fiber body;
step 5: carrying out hot pressing treatment on the dried stacked carbon fiber body, and removing a die after the hot pressing treatment to obtain a hot pressed carbon fiber blank;
Step 6: carbonizing the hot-pressed carbon fiber blank;
step 7: machining the hot-pressed carbon fiber blank to obtain a brake disc blank;
step 8: placing the brake disc blank into a boron nitride crucible and placing the boron nitride crucible into a high-temperature vacuum furnace for siliconizing treatment;
Step 9: and (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the carbon ceramic brake disc.
Wherein:
in the step 1, the included angle of 90 degrees is formed between the carbon fiber directions of the upper and lower carbon fiber unidirectional cloths of each chopped carbon fiber layer.
The chemical vapor deposition conditions in the step1 are as follows: the flow rate of methane is 80-180L/h, the flow rate of nitrogen is 3-20L/h, the deposition temperature is 950-1100 ℃, and the deposition time is 80-200h.
In the step3, the impregnating solution is 30-50wt% of phenolic resin alcohol solution.
And 5, the temperature of the hot press is 150 ℃, the pressure is 3-10MPa, and the hot press time is 4 hours.
The carbonization temperature in step 6 was 1000 ℃.
And (8) pre-placing pure silicon powder with the mass 1.1 times that of the brake disc blank into the boron nitride crucible in the step (8).
In the step 8, the siliconizing treatment temperature is 1600-1700 ℃, the heat preservation time is 2-4h, and the furnace pressure is less than 1000Pa.
Example 1
The embodiment provides a high-strength high-toughness carbon ceramic brake disc, which is prepared by the following steps:
Step 1: performing chemical vapor deposition on the carbon fibers, and chopping the deposited carbon fibers to a preset length to obtain chopped carbon fibers, wherein the chemical vapor deposition conditions are as follows: the flow rate of methane is 100L/h, the flow rate of nitrogen is 8L/h, the deposition temperature is 1000 ℃, and the deposition time is 120h;
Step 2: placing the carbon fiber unidirectional cloth in a mold with a certain shape, paving the chopped carbon fibers on the carbon fiber unidirectional cloth according to the thickness of 0.5mm, paving another layer of carbon fiber unidirectional cloth again by taking the direction of the carbon fibers as an included angle of 90 degrees, and stacking to the required thickness according to the mode to obtain a stacked carbon fiber body. The thickness of the carbon fiber unidirectional cloth is 0.5mm;
step 3: impregnating the stacked carbon fiber body in the mold by adopting a phenolic resin alcohol solution with the concentration of 40 wt%;
Step 4: drying the impregnated stacked carbon fiber body until the alcohol is completely volatilized;
step 5: placing the dried stacked carbon fiber body and the mould into a hot press together for hot pressing at the temperature of 150 ℃, the pressure of 5MPa and the time of 4 hours, and removing the mould after hot pressing treatment to obtain a hot-pressed carbon fiber blank;
step 6: carbonizing the hot-pressed carbon fiber blank at the carbonization temperature of 1000 ℃;
Step 7: machining the hot-pressed carbon fiber blank to obtain a brake disc blank, and preparing the ventilation duct and other characteristics of the product;
Step 8: putting the brake disc blank into a boron nitride crucible and putting the boron nitride crucible into a high-temperature vacuum furnace for siliconizing treatment, wherein pure silicon powder with the mass 1.1 times of that of the brake disc blank is put into the boron nitride crucible in advance, the siliconizing treatment temperature is 1650 ℃, the heat preservation time is 2 hours, and the hearth pressure is less than 1000Pa;
Step 9: and (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the high-strength high-toughness carbon ceramic brake disc.
Example 2
The embodiment provides a high-strength high-toughness carbon ceramic brake disc, which is prepared by the following steps:
Step 1: performing chemical vapor deposition on the carbon fibers, and chopping the deposited carbon fibers to a preset length to obtain chopped carbon fibers, wherein the chemical vapor deposition conditions are as follows: the flow rate of methane is 100L/h, the flow rate of nitrogen is 8L/h, the deposition temperature is 1000 ℃, and the deposition time is 120h;
step 2: placing the carbon fiber unidirectional cloth in a mold with a certain shape, paving the chopped carbon fibers on the carbon fiber unidirectional cloth according to the thickness of 0.9mm, paving another layer of carbon fiber unidirectional cloth again by taking the direction of the carbon fibers as an included angle of 90 degrees, and stacking to the required thickness according to the mode to obtain a stacked carbon fiber body. The thickness of the carbon fiber unidirectional cloth is 0.5mm;
step 3: impregnating the stacked carbon fiber body in the mold by adopting a phenolic resin alcohol solution with the concentration of 40 wt%;
Step 4: drying the impregnated stacked carbon fiber body until the alcohol is completely volatilized;
step 5: placing the dried stacked carbon fiber body and the mould into a hot press together for hot pressing at the temperature of 150 ℃, the pressure of 5MPa and the time of 4 hours, and removing the mould after hot pressing treatment to obtain a hot-pressed carbon fiber blank;
step 6: carbonizing the hot-pressed carbon fiber blank at the carbonization temperature of 1000 ℃;
Step 7: machining the hot-pressed carbon fiber blank to obtain a brake disc blank, and preparing the ventilation duct and other characteristics of the product;
Step 8: putting the brake disc blank into a boron nitride crucible and putting the boron nitride crucible into a high-temperature vacuum furnace for siliconizing treatment, wherein pure silicon powder with the mass 1.1 times of that of the brake disc blank is put into the boron nitride crucible in advance, the siliconizing treatment temperature is 1650 ℃, the heat preservation time is 2 hours, and the hearth pressure is less than 1000Pa;
Step 9: and (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the high-strength high-toughness carbon ceramic brake disc.
Example 3
The embodiment provides a high-strength high-toughness carbon ceramic brake disc, which is prepared by the following steps:
Step 1: performing chemical vapor deposition on the carbon fibers, and chopping the deposited carbon fibers to a preset length to obtain chopped carbon fibers, wherein the chemical vapor deposition conditions are as follows: the flow rate of methane is 100L/h, the flow rate of nitrogen is 8L/h, the deposition temperature is 1000 ℃, and the deposition time is 120h;
step 2: placing the carbon fiber unidirectional cloth in a mold with a certain shape, paving the chopped carbon fibers on the carbon fiber unidirectional cloth according to the thickness of 0.5mm, paving another layer of carbon fiber unidirectional cloth again by taking the direction of the carbon fibers as an included angle of 90 degrees, and stacking to the required thickness according to the mode to obtain a stacked carbon fiber body. The thickness of the carbon fiber unidirectional cloth is 0.7mm;
step 3: impregnating the stacked carbon fiber body in the mold by adopting a phenolic resin alcohol solution with the concentration of 40 wt%;
Step 4: drying the impregnated stacked carbon fiber body until the alcohol is completely volatilized;
step 5: placing the dried stacked carbon fiber body and the mould into a hot press together for hot pressing at the temperature of 150 ℃, the pressure of 5MPa and the time of 4 hours, and removing the mould after hot pressing treatment to obtain a hot-pressed carbon fiber blank;
step 6: carbonizing the hot-pressed carbon fiber blank at the carbonization temperature of 1000 ℃;
Step 7: machining the hot-pressed carbon fiber blank to obtain a brake disc blank, and preparing the ventilation duct and other characteristics of the product;
Step 8: putting the brake disc blank into a boron nitride crucible and putting the boron nitride crucible into a high-temperature vacuum furnace for siliconizing treatment, wherein pure silicon powder with the mass 1.1 times of that of the brake disc blank is put into the boron nitride crucible in advance, the siliconizing treatment temperature is 1650 ℃, the heat preservation time is 2 hours, and the hearth pressure is less than 1000Pa;
Step 9: and (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the high-strength high-toughness carbon ceramic brake disc.
Example 4
The embodiment provides a high-strength high-toughness carbon ceramic brake disc, which is prepared by the following steps:
Step 1: performing chemical vapor deposition on the carbon fibers, and chopping the deposited carbon fibers to a preset length to obtain chopped carbon fibers, wherein the chemical vapor deposition conditions are as follows: the flow rate of methane is 100L/h, the flow rate of nitrogen is 8L/h, the deposition temperature is 1000 ℃, and the deposition time is 120h;
Step 2: placing the carbon fiber unidirectional cloth in a mold with a certain shape, paving the chopped carbon fibers on the carbon fiber unidirectional cloth according to the thickness of 0.9mm, paving another layer of carbon fiber unidirectional cloth again by taking the direction of the carbon fibers as an included angle of 90 degrees, and stacking to the required thickness according to the mode to obtain a stacked carbon fiber body. The thickness of the carbon fiber unidirectional cloth is 0.7mm;
step 3: impregnating the stacked carbon fiber body in the mold by adopting a phenolic resin alcohol solution with the concentration of 40 wt%;
Step 4: drying the impregnated stacked carbon fiber body until the alcohol is completely volatilized;
step 5: placing the dried stacked carbon fiber body and the mould into a hot press together for hot pressing at the temperature of 150 ℃, the pressure of 5MPa and the time of 4 hours, and removing the mould after hot pressing treatment to obtain a hot-pressed carbon fiber blank;
step 6: carbonizing the hot-pressed carbon fiber blank at the carbonization temperature of 1000 ℃;
Step 7: machining the hot-pressed carbon fiber blank to obtain a brake disc blank, and preparing the ventilation duct and other characteristics of the product;
Step 8: putting the brake disc blank into a boron nitride crucible and putting the boron nitride crucible into a high-temperature vacuum furnace for siliconizing treatment, wherein pure silicon powder with the mass 1.1 times of that of the brake disc blank is put into the boron nitride crucible in advance, the siliconizing treatment temperature is 1650 ℃, the heat preservation time is 2 hours, and the hearth pressure is less than 1000Pa;
Step 9: and (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the high-strength high-toughness carbon ceramic brake disc.
Example 5
The embodiment provides a high-strength high-toughness carbon ceramic brake disc, which is prepared by the following steps:
Step 1: cutting the carbon fiber to a preset length to obtain a short carbon fiber;
Step 2: placing the carbon fiber unidirectional cloth in a mold with a certain shape, paving the chopped carbon fibers on the carbon fiber unidirectional cloth according to the thickness of 0.5mm, paving another layer of carbon fiber unidirectional cloth again by taking the direction of the carbon fibers as an included angle of 90 degrees, and stacking to the required thickness according to the mode to obtain a stacked carbon fiber body. The thickness of the carbon fiber unidirectional cloth is 0.5mm;
step 3: impregnating the stacked carbon fiber body in the mold by adopting a phenolic resin alcohol solution with the concentration of 40 wt%;
Step 4: drying the impregnated stacked carbon fiber body until the alcohol is completely volatilized;
step 5: placing the dried stacked carbon fiber body and the mould into a hot press together for hot pressing at the temperature of 150 ℃, the pressure of 5MPa and the time of 4 hours, and removing the mould after hot pressing treatment to obtain a hot-pressed carbon fiber blank;
step 6: carbonizing the hot-pressed carbon fiber blank at the carbonization temperature of 1000 ℃;
Step 7: machining the hot-pressed carbon fiber blank to obtain a brake disc blank, and preparing the ventilation duct and other characteristics of the product;
Step 8: putting the brake disc blank into a boron nitride crucible and putting the boron nitride crucible into a high-temperature vacuum furnace for siliconizing treatment, wherein pure silicon powder with the mass 1.1 times of that of the brake disc blank is put into the boron nitride crucible in advance, the siliconizing treatment temperature is 1650 ℃, the heat preservation time is 2 hours, and the hearth pressure is less than 1000Pa;
Step 9: and (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the high-strength high-toughness carbon ceramic brake disc.
Comparative example 1
The comparative example provides a carbon ceramic brake disc, wherein a brake disc blank of the carbon ceramic brake disc is formed by combining and superposing carbon fiber unidirectional cloth and a net tyre, and the preparation method comprises the following steps: and (3) stacking the carbon fiber unidirectional cloth and the carbon fiber net tire in a crossing way to obtain a carbon fiber preform, carrying out impregnation treatment on the carbon fiber preform, wherein the impregnation solution is phenolic resin alcohol solution with the concentration of 40wt%, and drying the impregnated carbon fiber preform until alcohol is completely volatilized. And (3) carbonizing the dried carbon fiber preform at 1000 ℃ for 4 hours. Then carrying out low-temperature graphitization treatment to obtain graphitized bodies, wherein the treatment temperature is 1700 ℃, and preserving heat for 2 hours; and (3) machining the graphitized body to obtain a brake disc blank, putting the brake disc blank into a boron nitride crucible, wherein the boron nitride crucible contains pure silicon powder with the mass 1.1 times of that of the brake disc blank, and then putting the brake disc blank into a high-temperature vacuum furnace for siliconizing treatment, wherein the temperature is 1650 ℃, the heat preservation time is 2 hours, and the furnace pressure is less than 1000Pa. And (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the carbon ceramic brake disc.
The carbon ceramic brake discs prepared in examples 1-4 and comparative example 1 above were tested for shear strength and flexural strength using GB/T15089-2001.
Test data are shown in table 1 below.
Table 1 carbon ceramic brake disc test data for examples 1-4 and comparative example 1
From the data of the examples and the comparative examples, the bending strength and the shearing strength of the carbon ceramic brake disc can be greatly enhanced by adopting the chopped carbon fiber to replace the common net tire layer. In example 5, the carbon fiber was not subjected to vapor deposition treatment, and the carbon fiber was not subjected to covering protection by the deposited carbon during the siliconizing treatment, so that the strength and toughness of the produced carbon ceramic brake disc were yet to be reinforced.
The foregoing disclosure is only illustrative of the preferred embodiments of the present invention and is not to be construed as limiting the scope of the invention, which is defined by the appended claims.
Claims (15)
1. The high-strength high-toughness carbon ceramic brake disc is characterized in that a brake disc blank of the high-strength high-toughness carbon ceramic brake disc comprises N carbon fiber unidirectional cloth layers and N chopped carbon fiber layers, wherein N is a natural number larger than 1, the carbon fiber unidirectional cloth layers and the chopped carbon fiber layers are stacked in a staggered mode, the thickness of the carbon fiber unidirectional cloth layers is 0.4-0.8mm, and the thickness of the chopped carbon fiber layers is 0.5-1mm.
2. The high-strength high-toughness carbon ceramic brake disc according to claim 1, wherein the carbon fiber unidirectional cloth layer comprises at least two unidirectional carbon fiber bundles, and two adjacent unidirectional carbon fiber bundles are spaced by 1-4mm.
3. The high strength, high toughness carbon ceramic brake disc according to claim 2, wherein the unidirectional carbon fiber bundles are 4-12K carbon fiber bundles.
4. The high strength, high toughness carbon ceramic brake disc according to claim 1, wherein carbon fiber bundles of the chopped carbon fibers in the chopped carbon fiber layer are 2-8K.
5. The high strength, high toughness carbon ceramic brake disc according to claim 4, wherein the length of the chopped carbon fibers in the chopped carbon fiber layer is 5-15mm.
6. The high strength and high toughness carbon ceramic brake disc according to claim 1, wherein the chopped carbon fiber layer comprises a carbon deposition layer coated on the outer surface of the chopped carbon fiber, and the thickness of the carbon deposition layer is 0.5-1.5 μm.
7. The high strength, high toughness carbon ceramic brake disc according to claim 1, wherein the high strength, high toughness carbon ceramic brake disc comprises 40-55% silicon carbide, 45-60% carbon and 4-15% silicon.
8. A method for preparing the high-strength high-toughness carbon ceramic brake disc as claimed in any one of claims 1 to 7, which is characterized by comprising the following steps:
Step 1: performing chemical vapor deposition on the carbon fibers and cutting the deposited carbon fibers to a preset length;
step 2: taking a plurality of carbon fiber unidirectional cloths, and continuously overlapping the carbon fiber unidirectional cloths and a layer of chopped carbon fibers in a mold in a combined mode until a stacked carbon fiber body with a preset thickness is obtained;
step 3: carrying out impregnation treatment on the stacked carbon fiber body;
step 4: drying the impregnated stacked carbon fiber body;
step 5: carrying out hot pressing treatment on the dried stacked carbon fiber body, and removing a die after the hot pressing treatment to obtain a hot pressed carbon fiber blank;
Step 6: carbonizing the hot-pressed carbon fiber blank;
step 7: machining the hot-pressed carbon fiber blank to obtain a brake disc blank;
step 8: placing the brake disc blank into a boron nitride crucible and placing the boron nitride crucible into a high-temperature vacuum furnace for siliconizing treatment;
Step 9: and (3) polishing the surface of the brake disc blank subjected to siliconizing treatment and processing the outer contour dimension to obtain the carbon ceramic brake disc.
9. The method for manufacturing a high-strength and high-toughness carbon ceramic brake disc according to claim 8, wherein an included angle of 90 degrees is formed between the carbon fiber directions of the upper carbon fiber unidirectional cloth and the lower carbon fiber unidirectional cloth of each chopped carbon fiber layer in the step 1.
10. The method for preparing the high-strength and high-toughness carbon ceramic brake disc according to claim 8, wherein the chemical vapor deposition conditions in the step 1 are as follows: the flow rate of methane is 80-180L/h, the flow rate of nitrogen is 3-20L/h, the deposition temperature is 950-1100 ℃, and the deposition time is 80-200h.
11. The method for preparing the high-strength and high-toughness carbon ceramic brake disc according to claim 8, wherein the impregnating solution in the step 3 is a phenolic resin alcohol solution with the concentration of 30-50 wt%.
12. The method for preparing the high-strength and high-toughness carbon ceramic brake disc according to claim 8, wherein the temperature of the hot press in the step 5 is 150 ℃, the pressure is 3-10MPa, and the hot pressing time is 4 hours.
13. The method for manufacturing a high-strength and high-toughness carbon ceramic brake disc according to claim 8, wherein the carbonization temperature in the step 6 is 1000 ℃.
14. The method for preparing the high-strength and high-toughness carbon ceramic brake disc according to claim 8, wherein in the step 8, pure silicon powder with the mass 1.1 times of that of a brake disc blank is put in the boron nitride crucible in advance.
15. The method for preparing the high-strength high-toughness carbon ceramic brake disc according to claim 8, wherein the siliconizing treatment temperature in the step 8 is 1600-1700 ℃, the heat preservation time is 2-4h, and the hearth pressure is less than 1000Pa.
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| CN202311810225.9A CN117962432A (en) | 2023-12-26 | 2023-12-26 | High-strength high-toughness carbon ceramic brake disc and preparation method thereof |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311810225.9A CN117962432A (en) | 2023-12-26 | 2023-12-26 | High-strength high-toughness carbon ceramic brake disc and preparation method thereof |
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