CN1896171A - Bi-continuous-phase composite friction material of foaming silicon carbide/metal, its member and preparation - Google Patents
Bi-continuous-phase composite friction material of foaming silicon carbide/metal, its member and preparation Download PDFInfo
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- CN1896171A CN1896171A CN 200610046242 CN200610046242A CN1896171A CN 1896171 A CN1896171 A CN 1896171A CN 200610046242 CN200610046242 CN 200610046242 CN 200610046242 A CN200610046242 A CN 200610046242A CN 1896171 A CN1896171 A CN 1896171A
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Abstract
A foaming silicon carbide/metal double-phase continuous composite friction material, its member and production are disclosed. The composite friction material consists of 15-60% foaming silicon carbide ceramic and 40-85% metal matrix. The procedure is carried out by synthesizing foaming silicon carbide ceramic with metal matrix and combing friction layer with metal layer. It can fulfill friction and bearing functions. It can be used for plane, track train, caterpillar vehicles, wheeled vehicles and ship.
Description
Technical field
The present invention relates to the technology of preparing of friction materials, specifically a kind of foam silicon carbon/metal composite friction materials and member and preparation method with co-continuous phase structure feature.
Background technology
Friction braking material is the critical material of consumption maximum in the breaking system of aircraft, rail transit train, endless-track vehicle and the modern means of communication such as wheeled vehicle, naval vessel, mainly comprise C/C matrix material, ferrous materials (cast iron, cast steel, forged steel), metal-base composites, mmaterial and semi-metallic or the like several major types, and used with component forms such as friction plate, retarding disc, bearing shell and brake linings.Wherein, semimetal braking material is mainly used in the breaking system of light vehicle, and other several classes are mainly used in the breaking system of heavy vehicles.Along with the above-mentioned vehicles constantly develop to high-power, high-speed, lightweight direction, its breaking system must be safer, reliable, durable and light-duty, thereby the demand of advanced friction braking material is become more urgent.
Advanced friction braking material should be able to keep stable frictional behaviour under different operating modes, and possesses low wear rate, high mechanical property, excellent resistance to deformation and survivability and low mass density simultaneously.Yet existing all kinds of friction braking materials can not satisfy these requirements well.
For example, be widely used in the powder metallurgy friction plate of aircraft and armored vehicle breaking system, comprise iron-based and copper based powder metallurgy friction wafer, have subject matters such as brake pressure height, braking response speed are slow, abrasion are big, cracky;
And for example, go up the carbon/carbon composite friction material of succeeing and using at aircraft (mainly being civilian aircraft) in recent decades, has extremely significant loss of weight advantage, but still exist the moisture absorption cause frictional coefficient low, in the sand and dust environment problem such as the serious and manufacturing cost height of abrasive wear, limited the expansion of its range of application;
For another example, with silicon carbide ceramics particle enhanced aluminum matrix composite is the ceramic/metal composite friction material of representative, have the advantage that loss of weight, noise reduction and frictional behaviour are not influenced by water, and have potential advantages in theory rubbing effect with the anti-attrition effect combination of pottery of metal.But, lack the mutual effect of contraction of intensive between ceramic particle and the aluminum substrate because this material belongs to 1-3 connecting-type matrix material in essence in structure.When high temperature friction, because the softening even rheology of aluminum substrate, the enhancement of ceramic particle weakens until disappearance, becomes abrasive material on the contrary, causes serious abrasive wear; Simultaneously, frictional coefficient increases fast, causes the adhesion with antithesis, occurs " locking ".There is The friction coefficient working conditions change serious problem of abrasive wear significantly and in the hot environment when in other words, ceramic particle enhanced metal composite uses as friction braking material.
In recent years, the porous ceramics skeleton of appearance strengthens the metal-base composites of overall enhanced, because of its distinctive 3-3 type (three-dimensional friction constituent element and three dimensional matrix) syndeton, makes the very strong mutual effect of contraction of formation between pottery and the metal.Thereby, as a kind of novel friction materials, this material is except having the advantage with the rubbing effect of metal and the anti-attrition effect perfect adaptation of pottery in theory, and pottery and strong constraint effect between the metal might make this material can keep stable frictional behaviour and low wear rate fully under different operating modes.Existing laboratory study and braking rig test result have not only confirmed above-mentioned deduction, but also find that it can show high braking response speed at very wide working pressure range.
Foamed ceramics, a kind of special porous ceramic film material, have pore texture, size and the ceramic volume fraction characteristics of regulation and control easily, not only be easy to compound with metal, and can also be according to different applications, by the regulation and control of ceramic phase volume fractional, realize the design of matrix material frictional behaviour.Therefore, the foamed ceramics/metal composite optimum in porous ceramics skeleton enhanced metal-base composites with co-continuous phase structure feature is done the friction materials use.
But existing foamed ceramics/metal composite is because when using as friction braking material, there is problem to be solved material self-characteristic and technology of preparing aspect below still existing:
The first, foamed ceramics intensity low (ultimate compression strength is generally less than 5MPa) behind metal formation matrix material, can not play the carrying effect substantially.When higher face was depressed friction, destroying very easily appearred in foamed ceramics, can not normally bring into play the friction member function of matrix material;
Second, the difference of thermal expansion coefficients of foamed ceramics and metal is very big, and compound back material internal produces very big internal stress, often causes the ceramic skeleton fracture, thereby form a large amount of both macro and micro defectives at material internal, seriously reduce the mechanical property and the heat conductivility of material;
The 3rd, vacuum infiltration recombining process, the basic skills of foamed ceramics/metal composite preparation both had been unfavorable for reducing the manufacturing cost of matrix material, also was unfavorable for the short flow process manufacturing of actual friction member.
The present invention will be at the problems referred to above, high-strength foam silicon carbide ceramics technology of preparing based on previous invention, utilize the pressure extrusion castmethod, take the internal stress measure of control, create friction stable performance, wear rate is low, resistance toheat good, physical strength is high, resistance to deformation and strong foam silicon carbon/metal co-continuous phase composite friction material and the member thereof of destructiveness, to satisfy aircraft, bullet train, armored vehicle and the vehicles such as other heavy-duty vehicle and the naval vessel demand to advanced friction braking material.
Summary of the invention
The object of the present invention is to provide a kind of foam silicon carbon/metal co-continuous phase composite friction material and member and preparation method.Have the advantages that with foam silicon carbon provided by the invention/metal co-continuous phase composite friction material resistance toheat is good, frictional behaviour is good, physical strength is high, processing performance is good.
Definition:
1, foam silicon carbon/metal co-continuous phase composite friction material---by certain volume fractional foam silicon carbon pottery and matrix metal by suitable complex method obtain have co-continuous phase structure feature, be the matrix material of basic function with the frictional behaviour.
2, foam silicon carbon/metal co-continuous phase composite friction material member---the member that combines by co-continuous phase composite materials friction layer and metal level (also claiming metal backing), can bring into play rubbing effect and carrying or load (power or thermal load) transfer function simultaneously.
3, matrix metal---refer in particular to the metallic substance that is compounded to form foam silicon carbon/metal co-continuous phase composite friction material with foam silicon carbon.It both can with the metal backing homogeneity in foam silicon carbon/metal co-continuous phase composite friction material member, also homogeneity not.
Technical scheme of the present invention is:
Foam silicon carbon/metal co-continuous phase composite friction material, mark meter by volume, its composition is made up of 15%～60% foam silicon carbon pottery, 85%～40% metallic matrix.Metal is castability copper and alloy, aluminium and alloy thereof, iron and an alloy thereof preferably.
Foam silicon carbon/metal co-continuous phase composite friction material member, its co-continuous phase composite materials friction layer can be in the 1/100-10/1 range with the metal layer thickness ratio.The material of metal level both with co-continuous phase composite materials friction layer in metallographic phase with homogeneous material, also dissimilar materials that can be different.When the friction materials member is friction plate, be steel as metal level, then can abbreviate steel backing as, the then corresponding steel backing friction plate that abbreviates as of friction plate.
Described foam silicon carbon/metal co-continuous phase composite friction material and member thereof, its foam silicon carbon that adopts is a kind of ceramic phase and three-dimensional mutual porous ceramics relation, present three-dimensional netted pattern on macro-scale that connects of hole existence wherein, the equivalent diameter of hole is: 0.1mm～10mm, porosity is 85%-40%, it was both fine and close to constitute the ceramic muscle of three dimensional network, also porous.When the pottery muscle was dense structure, corresponding foam silicon carbon was referred to as dense foam silicon carbide; When the pottery muscle was vesicular structure, corresponding foam silicon carbon was referred to as porous foam silicon carbide.
Described dense foam silicon carbide is the method that patent the provided preparation of 03134039.3 (publication number CN1600742A) by application number.Mark meter by weight, its composition is made up of 90%～98% silicon carbide and 10%～2% silicon; Constitute relative density 〉=99% of the unitary ceramic muscle of Polygons Closed loop, average grain size is at 50nm～10 μ m.
The preparation method of described porous foam silicon carbide is: after the method that the patent of utilizing number of patent application for 03134039.3 provides is prepared dense foam silicon carbide, further carry out high-temperature vacuum and take out the silicon processing.Processing condition are: temperature is that 1500 ℃～2250 ℃, vacuum tightness are 20Pa～2 * 10
-3Pa, insulation 20min～2h obtains porous foam silicon carbide, and the relative density of porous foam silicon carbide ceramics muscle is 95%～80%, and the equivalent diameter of hole is 0.5-100 μ m, and porosity is 5%-20%.In order to increase the micropore quantity in the ceramic muscle, can in being the ceramic slurry prescription of 03134039.3 component of pointing out, number of patent application add silica flour.The silica flour that adds accounts for the 1%-40% of slip gross weight, as pore-forming material.And then, obtain the porous foam silicon carbide ceramics of the micropore adjustable number in the ceramic muscle by preparation method of the present invention.
The preparation method of described foam silicon carbon/metal co-continuous phase composite friction material and member thereof is: will put into mould after the foam silicon carbide ceramics preheating that prepare, under air conditions, utilize the method for extrusion casting liquid matrix metal to be pressed in the three-dimensional communication hole of foam silicon carbide ceramics and solidify.Depanning then is chilled to room temperature, and size is on demand carried out machining again.After the metal beyond the foam silicon carbon zone was all processed removal, the material of gained was foam silicon carbon/metal co-continuous phase composite friction material; As keeping certain thickness metal level in a direction, then the material of gained is the foam silicon carbon/metal co-continuous phase composite friction material member of matrix metal homogeneity in metal backing and the foam silicon carbon/metal co-continuous phase composite friction material.
The preparation method of described foam silicon carbon/metal co-continuous phase composite friction material member is: the foam silicon carbide ceramics and the metal backing that prepare are combined into the pre-connection body, after preheating, put into mould, under air conditions, utilize the method for extrusion casting liquid matrix metal to be pressed in the three-dimensional communication hole of foam silicon carbide ceramics and solidify, realize that a step of foam silicon carbide ceramics, matrix metal and metal backing is compound.After the depanning, be chilled to room temperature, size is on demand carried out machining again, promptly obtains foam silicon carbon/metal co-continuous phase composite friction material member.The friction materials member can manufacture tabular, ring-type, tubulose, bar-shaped, bearing shell and other polymorphic structure according to the requirement of using breaking system.Can also earlier the pre-connection body of foam silicon carbon and foam silicon carbon pottery and metal backing be prepared into the desired shape and size that require of friction materials and member, after compound, remove excess metal by processing, finally obtain the composite friction material and the member of tabular, ring-type, tubulose, bar-shaped and other polymorphic structure.
The preparation method of described foam silicon carbon/metal co-continuous phase composite friction material and described foam silicon carbon/metal co-continuous phase composite friction material member, the compound of foam silicon carbon pottery, matrix metal and metal backing realizes that by extrusion casting method concrete steps are as follows:
(1) the pre-connection body with foam silicon carbon pottery or foam silicon carbon pottery and metal backing is preheating to 100 ℃～1200 ℃, and matrix metal (copper, aluminium, iron or their alloy) is heated to above 50 ℃～400 ℃ of fusing point;
(2) foam silicon carbon pottery after the preheating or foam silicon carbon pottery are put into mould with the pre-connection body of metal backing, pour the matrix metal of fusing into, the pressure of 50～200MPa and pressurize are 20 seconds～2 minutes in addition, afterwards, the compound of foam silicon carbon pottery, matrix metal and metal backing finished in release, depanning.
The mode that the fixed form of metal backing of the present invention and foam silicon carbon pottery adopts screw retention or clamps.Mould medial surface and foam silicon carbon pottery or foam silicon carbon pottery are 1～10mm with the distance at the pre-connection body edge of metal backing, are beneficial to keep the consistence of matrix metal liquation at the foam silicon carbide ceramics internal temperature, improve composite quality.
Matrix metal of the present invention is selected for use:
Copper alloys such as fine copper or brass, bronze, copper-nickel alloy, for example: chromium bronze (0.1～1.5Cr), iron bronze (1～15Fe), tinbronze, xantal etc.; Leaded brass, iron brass, manganese brass, silicon brass etc.
Fine aluminium or aluminium alloy etc., for example: Al-Si, Al-Cu, Al-Mg, Al-Zn, Al-Cu-Mg, Al-Cu-Mg-Fe-Ni series etc.
Iron alloy is selected carbon steel, low-alloy wear-resistant steel, cast iron, cast steel, bearing steel etc. for use, for example: BJ2, BJ2F, BJ5,45# steel, 60# steel, T8, T12, ZG40CrMn2SiMo, HT10-26, HT25-47, KT30-8, KTZ50-4, QT60-2 etc.
Metal backing of the present invention is selected iron alloy and superalloy, copper alloy and aluminium alloys etc. such as 65Mn steel, stainless steel, 45# steel, high temperature steel for use.The structure of metal backing can be: structures such as tabular, tubulose, bar-shaped and other different form, reserve the boring of some amount on it in advance.
Described foam silicon carbon/metal co-continuous phase composite friction material is the preparation method of member extremely, adds ceramic particle and (comprise SiC, Al in the foam silicon carbide ceramics mesh
2O
3Or SiO
2Deng), addition is the 1%-30% of foam silicon carbide ceramics gross weight, wherein ceramic particle utilizes caking agent to make particle, caking agent adopts resin or other caking agents (as ethyl silicate, water glass etc.), the add-on of caking agent is the 2%-20% of particle weight, and the grain graininess of manufacturing is: 0.1-3mm; Perhaps directly adopt ceramic particle to add in the mode of pine dress.Its objective is: on the one hand, reduce the expansion coefficient difference of foam silicon carbide ceramics and metallic matrix, eliminate the crackle that produces in the recombination process, improve composite quality; On the other hand, strengthen, the thermotolerance of matrix metal is improved, thereby make the thermotolerance of co-continuous phase composite materials also obtain corresponding raising by particle.
The preparation method of described foam silicon carbon/metal co-continuous phase composite friction material and member thereof, in the foam silicon carbide ceramics mesh, insert the friction constituent element, the friction constituent element comprises that the higher alloying element of some thermotolerances is (as iron, nickel, tungsten etc.) or lubricant component (graphite, molybdenumdisulphide etc.), addition is the 1%-30% of silicon carbide ceramics gross weight, wherein rub constituent element or lubricant component utilizes caking agent to make particle, caking agent adopts resin or other organic adhesives, the add-on of caking agent is the 2%-20% of particle weight, and the grain graininess of manufacturing is: 0.1-3mm; Perhaps directly adopt friction constituent element or lubricant component to add in the mode of pine dress.With thermotolerance that improves material or the temperature that reduces friction surface, improve the frictional behaviour of matrix material, also play the effect that reduces the matrix metal thermal expansivity simultaneously.
Add iron and graphite and make the reason of co-continuous phase composite materials thermotolerance raising mainly be, [specific heat capacity of Fe is 461J/ (kg a ℃) to the ratio of heat capacities copper of iron greatly
-1, the specific heat capacity of Cu is 385J/ (kg a ℃)
-1], thereby add the thermotolerance that iron powder has improved matrix copper to a certain extent; Main is that adding graphite has the high temperature lubricating effect, makes surface temperature rise reduction when rubbing, thereby plays the effect of protection matrix (Cu, Al, Fe or their alloy).
The present invention has following beneficial effect:
1, the foam silicon carbon/metal co-continuous phase composite friction material of the present invention's proposition, foamed ceramics and matrix metal form the three-dimensional networks relation of mutual perforation, make the very strong mutual constraint of formation between pottery and the metal, i.e. tight constraint relation.This tight constraint relation on the one hand, makes the rubbing effect of metal and the wear-resisting effect perfect adaptation of pottery; On the other hand, for matrix material possesses high rigidity, hardness, impelling strength and resistance to deformation, flow resistance ability simultaneously, and then make matrix material possess stable frictional behaviour and good heat-resistant provides the material structure basis.
2, several parameters such as the composition of volume fraction, ceramic particle and the friction constituent element of the composition that the frictional behaviour of foam silicon carbon/metal co-continuous phase composite friction material of proposing of the present invention can be by adjusting matrix metal, foamed ceramics and quantity design, thereby show the designability of good frictional behaviour.
3, the foam silicon carbon/metal co-continuous phase composite friction material of the present invention's proposition, two kinds of methods of the control material internal stress that is adopted, (this internal stress is enough to make the pottery fracture owing to the internal stress that difference of thermal expansion coefficients causes that obviously exists between pottery and the metallographic phase can to reduce three-dimensional bicontinuous composites very effectively, thereby form a large amount of crackles at material internal), avoid composite inner internal fissure to occur.Its result on the one hand, has improved the physical strength and the heat-transfer capability of matrix material significantly, guarantees the reliability of material usage; On the other hand, strengthen tight constraint and concerned the benefit of bringing to material friction performance and thermotolerance the subject of knowledge and the object of knowledge.When adopting when foamed ceramics adds ceramic particle or friction constituent element in the hole, can also reach the stable on heating purpose of further raising matrix material by the thermotolerance that improves matrix metal.
4, the foam silicon carbon/metal co-continuous phase composite friction material and the member thereof of the present invention's proposition, extrusion casting complex method under the preparation method who is adopted---the air atmosphere, efficiently, economy, both can directly obtain foam silicon carbon/metal co-continuous phase composite friction material, also can finish the compound of the geometry band back of the body composite friction material member identical with traditional friction member a step with size.These characteristics very help novel material directly substituting the conventional friction material member.
5, the foam silicon carbon/metal co-continuous phase composite friction material and the member thereof of the present invention's proposition, have that the designability of good frictional behaviour and very high stability, wear rate are low, resistance toheat good, physical strength is high, resistance to deformation and destructiveness is strong, manufacture method simple, can make characteristics such as abnormity component, thereby can be used as the novel high-performance friction braking material and obtain widespread use in the following aspects:
(1) be used for the brake of civilian aircraft and military aircraft, have that the brake response speed is fast, brake steadily, the low life-span of wear rate is long, braking ability little, required brake pressure affected by environment is low and advantage such as low cost.
(2) substitute traditional powder metallurgy brake flat, be used for the braking of military endless-track vehicle and heavy wheeled carrier vehicle, improve the work-ing life of brake facing and the overall efficiency of breaking system.
(3) substitute traditional metal or powder metallurgy brake flat, be used for civilian heavy endless-track vehicle (as crane, dozer, obstacles removing car etc.) and heavy wheeled carrier vehicle, improve the work-ing life of brake(-holder) block, reduce failure rate, improve security.
(4) substitute the ceramic particle reinforced metal base composites brake facing, be used for the braking of track vehicles such as bullet train, city, improve the braking reliability, increase the service life, reduce brake noise.
(5) substitute traditional powder metallurgy brake material and metal friction brake material, be used for the naval vessel breaking system, improve the braking reliability, increase the service life, reduce brake noise.
(6) the semi-metal friction brake sheet of alternative transmission is used for the sedan limousine breaking system, reduces noise, improves braking ability, increases the service life.
6, among the present invention, the composition of friction layer is consistent with the composition of foam silicon carbon/metal co-continuous phase composite friction material, and metal level both with friction layer in metallographic phase with material, other also different metal materials.The compound of foam silicon carbon pottery, matrix metal and metal backing all is that next step finishes the employing extrusion casting method at air atmosphere.Take two kinds of measures that can significantly reduce the matrix material internal stress, eliminated defectives such as co-continuous phase composite materials internal fissure.
Description of drawings
Fig. 1 is preparation technology's flow process of foam silicon carbon/metal co-continuous phase composite friction material and member thereof.
Fig. 2 a-c is the recombination process synoptic diagram of foam silicon carbon/metal co-continuous phase composite friction material and member thereof; Wherein, Fig. 2 a is the foam silicon carbon ceramic skeleton; Fig. 2 b is composite friction material and member recombination process synoptic diagram thereof, and 1 is metal alloy solution, and 2 is the foam silicon carbon pottery; Fig. 2 c is composite friction material and member thereof.
Fig. 3 a-b is a dense foam silicon carbide ceramics pattern; Wherein, Fig. 3 a is a macro morphology; Fig. 3 b is a microscopic appearance.
Fig. 4 a-b is a porous foam silicon carbide ceramics pattern; Wherein, Fig. 4 a is a macro morphology; Fig. 4 b is a microscopic appearance.
Fig. 5 a-b is porous foam silicon carbide ceramics and copper alloy compound pattern; Wherein, Fig. 5 a is a macro morphology, and Fig. 5 b is a foamed ceramics skeleton muscle interior microscopic pattern.
Fig. 6 is for adding Al
2O
3The pattern of particulate co-continuous phase composite materials.
Fig. 7 is for adding the co-continuous phase composite materials shape appearance figure of iron and graphite.
Fig. 8 a-b is foam silicon carbon/metal co-continuous phase composite friction material and member thereof; Wherein, Fig. 8 a is the foam silicon carbon ceramic skeleton; Fig. 8 b is composite friction material member-aircraft brake sheet still.
Fig. 9 is foam silicon carbon/metal co-continuous phase composite materials aircraft brake chip architecture synoptic diagram.
Figure 10 a-b is that foam silicon carbon/ceramic aperture is that the frictional coefficient, wear rate of the foam silicon carbon/copper co-continuous phase composite materials friction plate of 2mm and copper alloy is with variation of temperature; Wherein, Figure 10 a is the The friction coefficient variation of temperature; Figure 10 b is that wear rate is with variation of temperature.
Figure 11 a-b is that foam silicon carbon pottery aperture is the variation with load of the frictional coefficient, wear rate of the foam silicon carbon/copper co-continuous phase composite materials friction plate of 1.4mm and copper alloy.Wherein, Figure 11 a is the variation of The friction coefficient load; Figure 11 b is the variation of wear rate with load.
Figure 12 a-b is that foam silicon carbon/ceramic aperture is the variation with speed of the frictional coefficient, wear rate of the foam silicon carbon/copper co-continuous phase composite materials friction plate of 0.8mm and copper alloy.Wherein, Figure 12 a is the variation of The friction coefficient speed; Figure 12 b is the variation of wear rate with speed.
Among Figure 10 a-b, Figure 11 a-b, Figure 12 a-b, Cu represents the 85Cu-6Sn-6Zn-3Pb alloy, and 10%, 20%, 30% represents the volume fraction of foam silicon carbon/ceramic skeleton respectively.
Figure 13 a-b adds the pattern of SiC particulate foam silicon carbon/copper co-continuous phase composite materials; Wherein, Figure 13 a is a macro morphology, and Figure 13 b is a foamed ceramics skeleton muscle interior microscopic pattern.
Figure 14 foam silicon carbon/aluminium co-continuous phase composite friction material surface topography.
Figure 15 foam silicon carbon/aluminium co-continuous phase composite friction material, silicon-carbide particle enhanced aluminum composite frictional coefficient, wear rate vary with temperature curve.
Figure 16 a foam silicon carbon/aluminium co-continuous phase composite friction material frictional abrasion surface pattern, Figure 16 b silicon-carbide particle enhanced aluminum composite frictional abrasion surface pattern.
Figure 17 a volume fraction be respectively the co-continuous phase composite materials friction plate The friction coefficient coasting distance in two kinds of apertures of size of 10%, 20%, 30% change curve (macropore: 2mm, aperture: 0.8mm), the co-continuous phase composite materials wear rate in two kinds of apertures of Figure 17 b size and the relation of foamed ceramics volume integral number.
Figure 18 a volume fraction is respectively the co-continuous phase composite friction material The friction coefficient variation of temperature curve in two kinds of apertures of size of 10%, 20%, 30%, and Figure 18 b volume fraction is respectively the variation that the wear rate of the co-continuous phase composite friction material in two kinds of apertures of size of 10%, 20%, 30% raises with temperature.
Embodiment
The method that provides in the feature of the high strength foam silicon carbon pottery that the present invention relates to and preparation method and the patent application 03134039.3 is consistent.
Foam silicon carbon of the present invention/metal co-continuous phase composite friction material and member thereof, mark meter by volume, its composition is made up of 15%～60% foam silicon carbon metallic matrix ceramic and 85%～40%, wherein the aperture of foam silicon carbon pottery is: 0.1mm～10mm, porosity is 85%～40%.But but but metal is the alloy of alloy, iron and normal pressure melting thereof of alloy, fine aluminium and the normal pressure melting thereof of fine copper and normal pressure melting thereof.
1, the preparation of foam silicon carbon/copper co-continuous phase composite friction material member
Adopt the method for extrusion casting that fused copper alloy pressure injection is arrived in the foam silicon carbon pottery mesh, need size promptly to obtain foam silicon carbon/copper co-continuous phase composite friction material member, preparation process such as Fig. 1, Fig. 2 a-c through being machined to.
(1) high strength dense foam silicon carbide ceramics preparation
By number of patent application be: the method that 03134039.3 (publication number CN1600742A) provides prepares the high strength dense foam silicon carbide ceramics, as Fig. 3 a-b.
(2) porous silicon carbide foamed ceramics preparation
The method of the method for employing interpolation pore-forming material (silica flour) or high temperature, vacuum silica removal prepares porous foam silicon carbide/pottery, as Fig. 4 a-b, Fig. 5 a-b.
(3) selection of metal backing
Metal backing is selected materials such as iron alloys such as 65Mn steel, stainless steel, 45# steel or high temperature steel and superalloy, copper alloy for use.The structure of metal backing can be: structures such as tabular, tubulose, bar-shaped and other different form, reserve the boring of some amount on it in advance.
(4) foam silicon carbon pottery and metal backing is connected
Employing clamps or the mode of screw retention links together foam silicon carbide ceramics and metal backing, metal backing size and foamed ceramics skeleton consistent size or big 1～3mm.
(5) interpolation of component in the foam silicon carbon pottery mesh
Optionally add in foam silicon carbon pottery mesh: granularity is that the ceramic particle of 1～50 μ m (comprises SiC, Al
2O
3Or SiO
2Deng), as Fig. 6, Figure 13 a-b, or friction constituent element thermotolerance higher alloying element (as iron, nickel, tungsten etc.) granularity is 1～50 μ m, as Fig. 7, or lubricant component (graphite, molybdenumdisulphide etc.) granularity is 0.5～50 μ m, as Fig. 7.
(3) fusing of the preheating of foam silicon carbide ceramics skeleton and metal backing and copper alloy
Foam silicon carbon ceramic skeleton steel backing is preheating to 100 ℃～1200 ℃, and copper alloy is heated to above 50 ℃～400 ℃ of fusing point, adds insulating covering agent and deoxidation, slag hitting to improve the performance of molten alloy in fusion process.
(4) compound
Under air conditions, ceramic skeleton metal backing after the preheating is put into mould (material can be 45# steel or high temperature steel etc.), die size is than the big 1～10mm of steel backing size, pour the copper alloy of fusing into, pressurization: 50MPa～200MPa, pressurize: 20 seconds～2 minutes, make the fused copper alloy be full of all spaces, original position in the foam silicon carbon pottery and solidify and shrinkage cavity do not occur, obtain foam silicon carbon/metal co-continuous phase composite friction material member.
(5) depanning and machining
With being machined to the size that needs after foam silicon carbon/copper co-continuous phase composite friction material member depanning, promptly obtain foam silicon carbon/copper co-continuous phase composite friction material member, as Fig. 8 a-b, 9.The size of composite friction material member can be determined according to concrete application need.
Adopt the friction brake wafer working temperature of the present invention's preparation to be: room temperature～800 ℃; Braking or driving torque steadily, stable friction factor, wear rate low (seeing Figure 10 a-b, Figure 11 a-b, Figure 12 a-b); Mechanical property is: ballistic work is at 38.3～89.7kJ/m
-2, compressive strength exists: 400～560MPa, flexural strength exist: change in 260～370MPa scope; Silicon carbide ceramics foamy preparation technology improve reliable, compound be in air atmosphere a step finish, be suitable for to produce in enormous quantities.
2, the preparation of foam silicon carbon/aluminium co-continuous phase composite friction material member
Identical with the preparation method of foam silicon carbon/copper co-continuous phase composite friction material member.The temperature of fusion of aluminium alloy is lower, and recombination process is simple.The pattern of composite friction material member and frictional behaviour such as Figure 14-18.
3, the preparation of foam silicon carbon/iron co-continuous phase composite friction material member
Identical with the preparation method of foam silicon carbon/copper co-continuous phase composite friction material member.The temperature of fusion of iron alloy is higher, and is higher to the hot strength requirement of mould.
Below by embodiment in detail the present invention is described in detail.
Embodiment 1-21 is the preparation of foam silicon carbon/copper co-continuous phase composite friction material and member thereof.
Embodiment 22-41 is the preparation of foam silicon carbon/aluminium co-continuous phase composite friction material and member thereof.
Embodiment 42-51 is foam silicon carbon/extremely preparation of member of iron co-continuous phase composite friction material.
Earlier prepare the foam silicon carbon ceramic skeleton by number of patent application for 03134039.3 method that provides, size such as Fig. 8 a, Fig. 9.Wherein the thickness of foam silicon carbon pottery is 4mm, the big or small 0.5mm of mesh (aperture of foam silicon carbon pottery), in the foam silicon carbon ceramic/metal co-continuous phase composite materials, the foam silicon carbon ceramic volume fraction is 15%, utilize four centre holes to be screwed on the stainless (steel) wire of same size, be heated to the mould of putting into Φ 100mm after 300 ℃.
Adopt casting die, iron brass Hfe59-1-1 is heated to melting temperature (901 ℃) more than 200 ℃, pour in the mould after removing insulating covering agent and deoxidation, slag hitting, employing pressure is 50MPa, 20 seconds dwell times, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate (seeing Fig. 8 b).This friction plate has the advantages that resistance toheat is good, frictional behaviour is good, physical strength is high, processing performance is good.
Difference from Example 1 is:
Difference from Example 1 is:
Adopt the method for adding pore-forming material (silica flour) to prepare the porous foam silicon carbide ceramics, prepare in the ceramic slurry of foam silicon carbon pottery for 03134039.3 method that provides at number of patent application, prepare the porous foam silicon carbide ceramics by the method for adding the 20g silica flour in the prescription of 1 component of embodiment in this application.The relative density of porous foam silicon carbide ceramics muscle is 85%, and the equivalent diameter of hole is 10 μ m, and porosity is 15%.
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, be of a size of: to be that Φ 90mm is thick be the disk of 5mm to diameter, mesh size 0.2mm, volume fraction is 20%, steel backing is selected for use on the 65 manganese steel sheets of Φ 97mm, thick 4mm, on steel backing, bore the equally distributed through hole of spacing 10mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 4mm, the back side is Φ 6mm, utilize the screw of a M4 that foamed ceramics is fixed on the steel backing, be heated to the mould of putting into Φ 100mm after 500 ℃.
Adopt casting die, silicon brass Hsi80-3 is heated to melting temperature (900 ℃) more than 250 ℃, after removing dregs, employing pressure is 80MPa, 30 seconds dwell times, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate.
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, be of a size of: diameter is Φ 200mm, thickly is the disk of 5mm, mesh size 1mm, volume fraction is 30%, being screwed at diameter is on the stainless (steel) wire of Φ 210mm, is heated to the mould of putting into Φ 220mm after 800 ℃.
Adopt casting die, tinbronze QSn6-6-3 is heated to melting temperature (1019 ℃) more than 200 ℃, after removing dregs, employing pressure is 100MPa, 40 seconds dwell times, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate.
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, size sees that Fig. 8 a, Fig. 9, thickness are 4mm, mesh size 1mm, volume fraction is 40%, utilize four centre holes to be screwed on the stainless (steel) wire of same size, put into mould after being heated to 800 ℃.
Adopt casting die, chromium bronze (0.8Cr) is heated to 1380 ℃, pour in the mould after removing insulating covering agent and deoxidation, slag hitting, employing pressure is 120MPa, dwell time 2min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate (Fig. 8 b, Fig. 9).
Difference from Example 6 is:
Earlier prepare the foam silicon carbon pottery by number of patent application for 03134039.3 method that provides, size is seen Fig. 8 a, Fig. 9, and thickness is 5mm, mesh size 0.5mm, and volume fraction is 40%.Steel backing adopts the 45# steel, on steel backing, bore the equally distributed through hole of spacing 10mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 4mm, the back side is Φ 6mm, utilize the screw of a M4mm that foamed ceramics is fixed on the 45# steel steel backing, put into mould after being heated to 400 ℃.
Adopt casting die, chromium bronze (1.2Cr) is heated to 1380 ℃, pour in the mould in removing after insulating covering agent and deoxidation, the slag hitting, employing pressure is 100MPa, dwell time 1.5min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate.
Difference from Example 6 is:
Earlier prepare the foam silicon carbon pottery respectively for 03134039.3 method that provides by number of patent application, size is seen Fig. 8 a, Fig. 9, thickness is 4mm, mesh size 2mm, volume fraction is 50%, utilize a centre hole to be screwed and have the stainless steel back of uniform distribution through hole, the spacing of through hole is 10mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 3mm, the back side is Φ 6mm, utilize the screw of a M3 that foamed ceramics is fixed on the stainless steel back, put into mould after being heated to 800 ℃.
Adopt casting die, tinbronze QSn5-4-4 is heated to 1280 ℃, after removing dregs, pour in the mould, employing pressure is 120MPa, 30 seconds dwell times, is pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate.
Embodiment 9
Difference from Example 7 is:
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, under 1780 ℃ of temperature, vacuum 0.5Pa, 1 hour condition of soaking time, the remaining silicon of foamed ceramics skeleton muscle inside is taken out, obtain the porous foam silicon carbide ceramics, the relative density of porous foam silicon carbide ceramics muscle is 95%, the equivalent diameter of hole is 15 μ m, and porosity is 5%.Steel backing adopts the 45# steel, on steel backing, bore the equally distributed through hole of spacing 15mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 4mm, the back side is Φ 8mm, utilize the screw of a M4 that foamed ceramics is fixed on the 45# steel steel backing, put into mould after being heated to 400 ℃.
Adopt casting die, chromium bronze (1.2Cr) is heated to 1400 ℃, pour in the mould after removing insulating covering agent and deoxidation, slag hitting, employing pressure is 100MPa, dwell time 1.5min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate.
Difference from Example 7 is:
Adopt the method for adding pore-forming material (silica flour) to prepare the porous foam silicon carbide ceramics, prepare in the ceramic slurry of foam silicon carbon pottery for 03134039.3 method that provides at number of patent application, prepare the porous foam silicon carbide ceramics by the method for adding the 10g silica flour in the prescription of 2 components of embodiment in this application, the relative density of porous foam silicon carbide ceramics muscle is 85%, the equivalent diameter of hole is 20 μ m, and porosity is 15%.Steel backing adopts the 45# steel, on steel backing, bore the equally distributed through hole of spacing 15mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 4mm, the back side is Φ 6mm, utilize the screw of a M4 that foamed ceramics is fixed on the 45# steel steel backing, put into mould after being heated to 400 ℃.
Adopt casting die, iron bronze (6Fe) is heated to 1420 ℃, pour in the mould after removing insulating covering agent and slagging agent, employing pressure is 120MPa, dwell time 1min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate.
Embodiment 11
Earlier prepare the foam silicon carbon pottery by number of patent application for 03134039.3 method that provides, the foam silicon carbon ceramic skeleton is seen Fig. 8 a, Fig. 9, and thickness is 6mm, mesh size 1mm, and volume fraction is 40%, puts into mould after being heated to 800 ℃.
Adopt casting die, after chromium bronze (0.8Cr) is heated to 1380 ℃, pour in the mould after removing dregs, employing pressure is 120MPa, dwell time 2min is pressed in the foam silicon carbon ceramic skeleton, and being machined to needs size, wherein reserve the thick copper of 2mm and carry on the back, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---friction plate (Fig. 8 b, Fig. 9) as copper at the metal level of matrix material.
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application.The mesh of foamed ceramics size 0.5mm, volume fraction is 40%, external diameter is that Φ 250mm, internal diameter are two of Φ 200mm, high halfliners for 400mm.Steel backing adopts stainless steel, on steel backing, bore the equally distributed through hole of spacing 10mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 4mm, the back side is Φ 6mm, utilize the screw of four M4 that foamed ceramics is fixed on the stainless steel steel backing, put into external diameter after being heated to 400 ℃ and be Φ 270mm, internal diameter and be Φ 180mm, highly be the mould of 600mm.
Adopt casting die, chromium bronze (1.2Cr) is heated to 1380 ℃, pour in the mould in removing behind insulating covering agent and the slagging agent, employing pressure is 100MPa, dwell time 1.5min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/copper co-continuous phase composite friction material member---the brake bearing shell.This brake bearing shell has the advantages that resistance toheat is good, frictional behaviour is good, physical strength is high, processing performance is good.
Embodiment 13
Be copper alloy aluminium bronze QAl11-6-6 with the difference of embodiment 2.
Be with the difference of embodiment 3: employing pressure is 80MPa.
Embodiment 15
Be with the difference of embodiment 6: copper alloy is selected iron bronze (8Fe) for use.
Be with the difference of embodiment 5: the dwell time is 0.5min.
Embodiment 17
Be with the difference of embodiment 8: the interpolation granularity is that iron powder and the granularity of 7 μ m are the carbon dust of 10 μ m in the mesh of foam silicon carbon pottery, and addition is respectively 5% and 15% of foam silicon carbon pottery gross weight, directly adds in pine dress mode.
Be with the difference of embodiment 6: copper is poured in the mould after selecting for use 99.9% fine copper to be heated to 1300 ℃.
Embodiment 19
Be with the difference of embodiment 2: adding granularity in the mesh of foam silicon carbon pottery is the silicon carbide micro-powder of 5 μ m, addition is respectively 10% of foam silicon carbon pottery gross weight, adopt the resin manufacture particle, the add-on of resin is 10% of a silicon carbide micro-powder weight, and pine adds and adds behind the particle of manufacturing 0.5mm.
Be with the difference of embodiment 6: steel backing is selected the 65Mn steel for use.
Embodiment 21
Difference from Example 6 is:
The aperture of foam silicon carbon ceramic skeleton is respectively: 2mm (macropore), 1.4mm (mesopore), 0.8mm (aperture), body material is selected the 85Cu-6Sn-6Zn-3Pb alloy for use.Be cast into foam silicon carbon/copper co-continuous phase composite friction material member---friction plate at 1200 ℃, 120MPa condition, the pair of rubbing selected for use the Si of Φ 6mm
3N
4Ceramic Balls.Frictional behaviour such as Figure 10-12.
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application.Wherein the foam silicon carbon pottery is of a size of: external diameter is that Φ 85mm, internal diameter are Φ 75mm, thickly are the annulus of 3mm, the big or small 0.5mm of mesh (aperture of foam silicon carbide ceramics), volume fraction is 15%, being screwed at external diameter is that Φ 97mm, internal diameter are on the 45# steel loop of Φ 75mm, thick 10mm, is heated to the mould of putting into Φ 100mm after 300 ℃.
Adopt casting die, cast aluminium alloy ZL101 is heated to melting temperature more than 150 ℃, pour in the mould after removing insulating covering agent and slagging agent, employing pressure is 50MPa, 20 seconds dwell times, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate.This friction plate has the advantages that resistance toheat is good, frictional behaviour is good, physical strength is high, processing performance is good.
Embodiment 23
Be with the difference of embodiment 22:
Be with the difference of embodiment 22:
Adopt the method for adding pore-forming material (silica flour) to prepare the porous foam silicon carbide ceramics, prepare in the ceramic slurry of foam silicon carbon pottery for 03134039.3 method that provides at number of patent application, prepare the porous foam silicon carbide ceramics by the method for adding the 20g silica flour in the prescription of 3 components of embodiment in this application, the relative density of porous foam silicon carbide ceramics muscle is 88%, the equivalent diameter of hole is 20 μ m, and porosity is 12%.
Embodiment 25
Be with the difference of embodiment 22:
Be with embodiment 22 differences:
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application.Wherein the foam silicon carbon pottery is of a size of: external diameter is that Φ 90, internal diameter are Φ 75mm, thickly are the annulus of 3mm, mesh size 0.2mm, volume fraction is 20%, being screwed at external diameter is that Φ 97mm, internal diameter are on the 45# steel loop of Φ 75mm, thick 10mm, steel loop evenly bores the straight hole of Φ 4mm, pitch of holes is 5mm, is heated to the mould of putting into Φ 100mm after 500 ℃.
Adopt casting die, rust-preventing aluminum alloy LF5 is heated to melting temperature more than 200 ℃, after removing dregs, employing pressure is 80MPa, 30 seconds dwell times, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate.
Embodiment 27
Be with embodiment 22 differences:
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application.Wherein the foam silicon carbon pottery is of a size of: external diameter is that Φ 200mm, internal diameter are Φ 160mm, thickly are the annulus of 3mm, mesh size 1mm, volume fraction is 30%, being screwed at external diameter is that Φ 210mm, internal diameter are on the stainless (steel) wire of Φ 160mm, thick 2mm, is heated to the mould of putting into Φ 220mm after 800 ℃.
Adopt casting die, cast aluminium alloy ZL101 is heated to melting temperature more than 200 ℃, after removing dregs, employing pressure is 100MPa, 40 seconds dwell times, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate.
Embodiment 28
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, wherein the foam silicon carbon pottery is of a size of: the disk of Φ 90 * 6mm, mesh size 1mm, volume fraction is 40%, utilize four centre holes to be screwed on the stainless (steel) wire of same size, put into mould after being heated to 800 ℃.
Adopt casting die, cast aluminium alloy ZL109 is heated to melting temperature more than 150 ℃, pour in the mould after removing insulating covering agent and slagging agent, employing pressure is 120MPa, dwell time 2min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate (Fig. 8 b, Fig. 9).
Embodiment 29
Be with embodiment 28 differences:
Earlier prepare the foam silicon carbon pottery by number of patent application for 03134039.3 method that provides, size such as Fig. 8 a, Fig. 9, thickness are 4mm, mesh size 0.5mm, and volume fraction is 40%.Steel backing adopts the 45# steel, on steel backing, bore the equally distributed through hole of spacing 10mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 4mm, the back side is Φ 6mm, utilize the screw of a M4 that foamed ceramics is fixed on the 45# steel steel backing of same size, put into mould after being heated to 400 ℃.
Adopt casting die, rust-preventing aluminum alloy LF11 is heated to melting temperature more than 150 ℃, pour in the mould in removing behind insulating covering agent and the slagging agent, employing pressure is 100MPa, dwell time 1.5min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate.
Be with embodiment 28 differences:
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application.Utilize a centre hole to be screwed stainless steel back at same size with uniform distribution through hole, the spacing of through hole is 10mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 3mm, the back side is Φ 6mm, utilize the screw of a M3 that foamed ceramics is fixed on the stainless steel back, put into mould after being heated to 800 ℃.
Adopt casting die, rust-preventing aluminum alloy LF11 is heated to melting temperature more than 150 ℃, after removing dregs, pour in the mould, employing pressure is 120MPa, and dwell time 30Sec is pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate.
Embodiment 31
Be with embodiment 28 differences:
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, under 1780 ℃ of temperature, vacuum 0.5Pa, 1 hour condition of soaking time, the remaining silicon of foamed ceramics skeleton muscle inside is taken out, obtain the porous foam silicon carbide ceramics, the relative density of porous foam silicon carbide ceramics muscle is 80%, the equivalent diameter of hole is 100 μ m, and porosity is 20%.Steel backing adopts the 45# steel, on steel backing, bore the equally distributed through hole of spacing 15mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 4mm, the back side is Φ 8mm, utilize the screw of a M4 that foamed ceramics is fixed on the 45# steel steel backing of same size, put into mould after being heated to 400 ℃.
Adopt casting die, rust-preventing aluminum alloy LF8 is heated to melting temperature more than 220 ℃, pour in the mould after removing insulating covering agent and slagging agent, employing pressure is 100MPa, dwell time 1.5min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate.
Embodiment 32
Be with embodiment 28 differences:
Adopt the method for adding pore-forming material (silica flour) to prepare the porous foam silicon carbide ceramics, prepare in the ceramic slurry of foam silicon carbon pottery for 03134039.3 method that provides at number of patent application, prepare the porous foam silicon carbide ceramics by the method for adding the 10g silica flour in the prescription of 4 components of embodiment in this application, the relative density of porous foam silicon carbide ceramics muscle is 92%, the equivalent diameter of hole is 30 μ m, and porosity is 8%.Steel backing adopts the 45# steel, on steel backing, bore the equally distributed through hole of spacing 15mm, aperture size be with foamed ceramics contact surface aperture be that the aperture size at Φ 4mm, the back side is Φ 6mm, utilize the screw of a M4 that foamed ceramics is fixed on the 45# steel steel backing of same size, put into mould after being heated to 400 ℃.
Adopt casting die, cast aluminium alloy ZL101 is heated to melting temperature more than 150 ℃, pour in the mould after removing insulating covering agent and slagging agent, employing pressure is 120MPa, dwell time 1min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate.
Embodiment 33
Earlier prepare the foam silicon carbon pottery by number of patent application for 03134039.3 method that provides, the foam silicon carbon ceramic skeleton is of a size of: the disk of Φ 150 * 5mm.Mesh size 1mm, volume fraction is 60%, puts into mould after being heated to 800 ℃.
Adopt casting die, forging aluminium alloy LD5 is heated to fusing point more than 180 ℃, pour in the mould after removing dregs, employing pressure is 120MPa, dwell time 2min is pressed in the foam silicon carbon ceramic skeleton, and being machined to needs size, wherein reserve the thick aluminium of 2mm and carry on the back, can obtain foam silicon carbon/aluminium co-continuous phase composite friction material member---friction plate as aluminium at the metal level of matrix material.
Embodiment 34
Be with the difference of embodiment 29: adding granularity in the mesh of foam silicon carbon pottery is the carbon dust of 10 μ m, addition is 15% of a foam silicon carbon pottery gross weight, adopt phenolic aldehyde or epoxy adhesive to make particle, the add-on of binding agent is 20% of a silicon carbide micro-powder weight, and the particle pine of making 0.2mm adds and adds.
Embodiment 35
Be with the difference of embodiment 24: employing pressure is 80MPa.
Embodiment 36
Be aluminium alloy aluminium zinc alloy ZL401 with the difference of embodiment 22.
Embodiment 37
Be with the difference of embodiment 28: aluminium alloy is selected duralumin LY12 for use.
Embodiment 38
Be with the difference of embodiment 27: the dwell time is 1min.
Embodiment 17
Be aluminium alloy aluminium magnesium alloy ZL302 with the difference of embodiment 22.
Embodiment 39
Be with the difference of embodiment 28: aluminium is poured in the mould after selecting for use 99.9% fine aluminium to be heated to 800 ℃.
Embodiment 40
Be with the difference of embodiment 24: adding granularity in the mesh of foam silicon carbon pottery is the silicon carbide micro-powder of 5 μ m, addition is 8% of a foam silicon carbon pottery gross weight, adopted the ethyl silicate binding agent to make particle, the add-on of binding agent is 2% of a silicon carbide micro-powder weight, and the particle pine of making 0.2mm adds and adds.
Embodiment 41
Be with the difference of embodiment 28: steel backing is selected the 65Mn steel for use.
Embodiment 42
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, wherein the foam silicon carbon pottery is of a size of: external diameter is that Φ 95mm, internal diameter are Φ 75mm, thickly are the annulus of 3mm, the big or small 0.5mm of mesh (aperture of foam silicon carbide ceramics), volume fraction is 15%, utilizes four screw retention being heated to the mould of putting into Φ 100mm after 300 ℃ on the stainless (steel) wire of same size.
Adopt casting die, the 45# steel is heated to melting temperature more than 150 ℃, pour in the mould after removing insulating covering agent and slagging agent, employing pressure is 50MPa, 20 seconds dwell times were pressed in the foam silicon carbon ceramic skeleton, and being machined to needs size, reserve the steel backing of 1mm at the back side of surface of friction, can obtain foam silicon carbon/iron co-continuous phase composite friction material member---friction plate.
Embodiment 43
Be with the difference of embodiment 22:
Adopt the method for adding pore-forming material (silica flour) to prepare the porous foam silicon carbide ceramics, prepare in the ceramic slurry of foam silicon carbon pottery for 03134039.3 method that provides at number of patent application, prepare the porous foam silicon carbide ceramics by the method for adding the 15g silica flour in the prescription of 5 components of embodiment in this application, the relative density of porous foam silicon carbide ceramics muscle is 83%, the equivalent diameter of hole is 30 μ m, and porosity is 17%.
Embodiment 44
Be with the difference of embodiment 22:
Embodiment 45
Be with embodiment 22 differences:
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application.Wherein the foam silicon carbon pottery is of a size of: external diameter is that Φ 200mm, internal diameter are Φ 160mm, thickly are the annulus of 3mm, mesh size 1mm, volume fraction is 30%, being screwed at external diameter is that Φ 210mm, internal diameter are on the stainless (steel) wire of Φ 160mm, thick 2mm, is heated to the mould of putting into Φ 220mm after 800 ℃.
Adopt casting die, the BJ2 carbon steel is heated to melting temperature more than 200 ℃, after removing dregs, employing pressure is 100MPa, 40 seconds dwell times, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/iron co-continuous phase composite friction material member---friction plate.
Embodiment 46
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, wherein the foam silicon carbon pottery is of a size of: the disk of Φ 90 * 6mm, mesh size 1mm, volume fraction is 40%, is screwed to put into mould be heated to 800 ℃ on diameter is the stainless (steel) wire of Φ 100mm after.
Adopt casting die, cast iron HT15-33 is heated to melting temperature more than 150 ℃, pour in the mould after removing insulating covering agent and slagging agent, employing pressure is 120MPa, dwell time 2min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/iron co-continuous phase composite friction material member---friction plate.
Embodiment 47
Be with embodiment 46 differences:
Earlier prepare the foam silicon carbon pottery by number of patent application for 03134039.3 method that provides, size such as Fig. 8 a, Fig. 9, thickness are 5mm, mesh size 2mm, and volume fraction is 50%, puts into mould after being heated to 800 ℃.
Adopt casting die, cast iron KTZ50-4 be heated to melting temperature more than 250 ℃, remove dregs after, pour in the mould, employing pressure is 120MPa, dwell time 30Sec, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, and the face opposite with surface of friction stays the cast iron back of the body of 2mm.Can obtain foam silicon carbon/iron co-continuous phase composite friction material member---friction plate.
Embodiment 48
Be with embodiment 47 differences:
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, under 1780 ℃ of temperature, vacuum 0.5Pa, 1 hour condition of soaking time, the remaining silicon of foamed ceramics skeleton muscle inside is taken out, obtain the porous foam silicon carbide ceramics, the relative density of porous foam silicon carbide ceramics muscle is 85%, the equivalent diameter of hole is 15 μ m, and porosity is 15%.
Adopt casting die, low-alloy wear-resistant steel ZG40GrMn2SiMo is heated to melting temperature more than 220 ℃, pour in the mould after removing insulating covering agent and slagging agent, employing pressure is 100MPa, dwell time 1.5min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/iron co-continuous phase composite friction material member---friction plate.
Embodiment 49
Earlier prepare the foam silicon carbon pottery for 03134039.3 method that provides by number of patent application, mesh size 0.5mm, volume fraction is 40%, external diameter is that Φ 250mm, internal diameter are two of Φ 200mm, high halfliners for 400mm.Putting into external diameter after being heated to 400 ℃ is that Φ 270mm, internal diameter are that Φ 180mm, height are the mould of 600mm.
Adopt casting die, antifriction cast iron KmTBCr20Mo2Cu1 is heated to melting temperature more than 300 ℃, pour in the mould in removing behind insulating covering agent and the slagging agent, employing pressure is 100MPa, dwell time 1.5min, be pressed in the foam silicon carbon ceramic skeleton, being machined to needs size, can obtain foam silicon carbon/iron co-continuous phase composite friction material member---the brake bearing shell.
Be with embodiment 46 differences: iron is selected cast iron QT60-2 for use.
Embodiment 51
Be with the difference of embodiment 46: adding granularity in the mesh of foam silicon carbon pottery is the silicon carbide micro-powder of 5 μ m, addition is 5% of a foam silicon carbon pottery gross weight, adopt sodium silicate binder to make particle, the add-on of binding agent is 5% of a silicon carbide micro-powder weight, and the particle pine of making 0.2mm adds and adds.
Claims (16)
1, a kind of foam silicon carbon/metal co-continuous phase composite friction material is characterized in that: mark meter by volume, its composition is made up of 15%～60% foam silicon carbon pottery and 85%～40% matrix metal.
2, by the described foam silicon carbon of claim 1/metal co-continuous phase composite friction material, it is characterized in that: foam silicon carbon is a kind of ceramic phase and three-dimensional mutual porous ceramics relation, present three-dimensional netted pattern on macro-scale that connects of hole existence wherein, the equivalent diameter of hole is: 0.1mm～10mm, porosity is: 85%-40%, the ceramic muscle that constitutes three dimensional network are fine and close or porous; When the pottery muscle was dense structure, corresponding foam silicon carbon was referred to as dense foam silicon carbide; When the pottery muscle was vesicular structure, corresponding foam silicon carbon was referred to as porous foam silicon carbide.
3, by the described foam silicon carbon of claim 1/metal co-continuous phase composite friction material, it is characterized in that: matrix metal is fine copper, fine aluminium, pure iron or their alloy;
Copper alloy is selected fine copper for use and can be comprised the chromium bronze that contains 0.1～1.5wt%Cr, the iron bronze that contains 1～15wt%Fe, tinbronze, xantal, leaded brass, iron brass, manganese brass or silicon brass at the copper alloy of normal pressure melting;
Aluminium alloy is selected fine aluminium for use and can be comprised Al-Si, Al-Cu, Al-Mg, Al-Zn, Al-Cu-Mg or Al-Cu-Mg-Fe-Ni series at the aluminium alloy of normal pressure melting;
Iron alloy is selected carbon steel, low-alloy wear-resistant steel, bearing steel, cast iron or cast steel for use, comprises BJ2, BJ2F, BJ5,45# steel, 60# steel, T8, T12, ZG40CrMn2SiMo, HT10-26, HT25-47, KT30-8, KTZ50-4, QT60-2.
4, press the preparation method of the described foam silicon carbon of claim 1/metal co-continuous phase composite friction material, it is characterized in that: compound under air conditions, by Squeeze Casting liquid matrix metal is pressed in the three-dimensional communication hole of foam silicon carbide ceramics and solidifies, thereby realize the compound of foam silicon carbon pottery, matrix metal; Concrete steps are as follows:
(1) the foam silicon carbon pottery is preheating to 100 ℃～1200 ℃, matrix metal is heated to above 50 ℃～400 ℃ of fusing point;
(2) the foam silicon carbon pottery after the preheating is put into mould, pour the matrix metal of fusing into, the pressure of 50～200MPa and pressurize are 20 seconds～2 minutes in addition, and afterwards, the compound of foam silicon carbon pottery, matrix metal finished in release, depanning.
5, by the preparation method of the described foam silicon carbon of claim 4/metal co-continuous phase composite friction material, it is characterized in that: the distance at mould medial surface and foam silicon carbon pottery edge is 1～10mm.
6, press the preparation method of the described foam silicon carbon of claim 4/metal co-continuous phase composite friction material, prepare, soak extension, hot-pressing densification, pyrolysis, filling carbon skeleton centre hole, siliconising by slip, preparation dense foam silicon carbide, it is characterized in that: after preparing dense foam silicon carbide, further carry out high-temperature vacuum and take out silicon and handle: processing condition are: temperature is that 1500 ℃～2250 ℃, vacuum tightness are 20Pa～2 * 10
-3Pa, insulation 20min～2h obtains porous foam silicon carbide.
7, the preparation method according to the described foam silicon carbon of claim 4/metal co-continuous phase composite friction material is it is characterized in that: add the 1%-40% silica flour that accounts for the slip gross weight in the slip preparation, as pore-forming material.
8, by the preparation method of the described foam silicon carbon of claim 4/metal co-continuous phase composite friction material, it is characterized in that: in foam silicon carbon pottery mesh, insert ceramic particle, comprise SiC, Al
2O
3Or SiO
2Addition is the 1%-30% of foam silicon carbon pottery gross weight, and wherein ceramic particle utilizes caking agent to make particle, and caking agent adopts resin or other organic adhesives, the add-on of caking agent is the 2%-20% of particle weight, and the grain graininess of manufacturing is: 0.1-3mm; Perhaps directly adopt ceramic particle to add in the mode of pine dress.
9, preparation method by the described foam silicon carbon of claim 4/metal co-continuous phase composite friction material, it is characterized in that: in the foam silicon carbide ceramics mesh, insert the friction constituent element, the friction constituent element comprises the alloying element that some thermotolerances are higher: iron, nickel, tungsten, perhaps lubricant component: graphite, molybdenumdisulphide, addition is the 1%-30% of foam silicon carbon pottery gross weight, wherein rub constituent element or lubricant component utilizes caking agent to make particle, caking agent adopts resin or other organic adhesives, the add-on of caking agent is the 2%-20% of particle weight, and the grain graininess of manufacturing is: 0.1-3mm; Perhaps directly adopt friction constituent element or lubricant component to add in the mode of pine dress.
10, press the preparation method of the described foam silicon carbon of claim 4/metal co-continuous phase composite friction material, it is characterized in that: earlier foam silicon carbon is prepared into the desired shape and size of friction materials, after compound, remove excess metal by processing, finally obtain the composite friction material of tabular, ring-type, tubulose, bar-shaped and other polymorphic structure.
11, according to the member of the described foam silicon carbon of claim 1/metal co-continuous phase composite friction material, it is characterized in that: this member is made up of described foam silicon carbon/metal co-continuous phase composite friction material friction layer and metal level, and friction layer can be in the 1/100-10/1 range with the metal layer thickness ratio; The material of metal level adopt with co-continuous phase composite materials friction layer in the same homogeneous material of metallographic phase or different dissimilar materialss.
12, by the described foam silicon carbon of claim 11/metal co-continuous phase composite friction material member, it is characterized in that: metal level is selected 65Mn steel, stainless steel, 45# steel or high temperature steel iron alloy and superalloy, copper alloy or aluminium alloy for use; The structure of metal level is: tabular, tubulose, bar-shaped or other different form structure, reserve boring on it in advance.
13, press the preparation method of the described foam silicon carbon of claim 11/metal co-continuous phase composite friction material member, it is characterized in that: compound under air conditions, by Squeeze Casting liquid matrix metal is pressed in the three-dimensional communication hole of foam silicon carbide ceramics and solidifies, thereby realize the compound of foam silicon carbon pottery, matrix metal and metal level; Concrete steps are as follows:
(1) the pre-connection body with foam silicon carbon pottery and metal level is preheating to 100 ℃～1200 ℃, and matrix metal is heated to above 50 ℃～400 ℃ of fusing point;
(2) pottery of the foam silicon carbon after the preheating and the pre-connection body of metal level are put into mould, pour the matrix metal of fusing into, the pressure of 50～200MPa and pressurize are 20 seconds～2 minutes in addition, afterwards, the compound of foam silicon carbon pottery, matrix metal and metal level finished in release, depanning.
14, by the preparation method of the described foam silicon carbon of claim 13/metal co-continuous phase composite friction material member, it is characterized in that: the mode that the fixed form of metal level and foam silicon carbon pottery adopts screw retention or clamps.
15, by the preparation method of the described foam silicon carbon of claim 13/metal co-continuous phase composite friction material member, it is characterized in that: mould medial surface and foam silicon carbon pottery are 1～10mm with the distance at the pre-connection body edge of metal level.
16, press the preparation method of the described foam silicon carbon of claim 13/metal co-continuous phase composite friction material member, it is characterized in that: the desired shape and size that earlier the foam silicon carbon pottery and the pre-connection body of metal level are prepared into member, after compound, remove excess metal by processing, finally obtain the composite friction material and the member of tabular, ring-type, tubulose, bar-shaped and other polymorphic structure.
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Assignee: Liaoning Zhuoyi New Material Co., Ltd. Assignor: Institute of metal research, Chinese Academy of Sciences Contract record no.: 2011210000121 Denomination of invention: Preparation method of bi-continuous-phase composite friction material member of foaming silicon carbide/metal Granted publication date: 20090527 License type: Exclusive License Open date: 20070117 Record date: 20110824 |