CN216555078U - Aluminum-based alloy brake disc with wear-resistant coating for railway vehicle - Google Patents
Aluminum-based alloy brake disc with wear-resistant coating for railway vehicle Download PDFInfo
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- CN216555078U CN216555078U CN202121903349.8U CN202121903349U CN216555078U CN 216555078 U CN216555078 U CN 216555078U CN 202121903349 U CN202121903349 U CN 202121903349U CN 216555078 U CN216555078 U CN 216555078U
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Abstract
The utility model provides an aluminum-based alloy brake disc with a wear-resistant coating for a railway vehicle, which comprises an aluminum-based alloy brake disc base body, wherein the aluminum-based alloy brake disc base body adopts a national standard 7075T651 alloy, a wear-resistant alloy layer is sprayed on the surface of the aluminum-based alloy brake disc base body, the bonding strength between the wear-resistant alloy layer and the aluminum-based alloy brake disc base body is not less than 70MPa, the thickness of the wear-resistant alloy layer is 0.2-0.5 mm, a rough surface is formed on the surface of the wear-resistant layer, and the surface roughness is as follows: ra0.8-1.6. The utility model solves the problems of heavy weight and energy waste of the existing cast steel and cast iron material brake disc, overcomes the defects of non-wear resistance and the like of the latest aluminum-based alloy brake disc, perfectly unifies light weight and high wear resistance, and provides a brand-new and advanced brake disc for the railway vehicle.
Description
Technical Field
The utility model relates to an aluminum-based alloy brake disc with a wear-resistant coating for a railway vehicle.
Background
The brake disc is the main safety key part of all rail vehicles, and no matter the car, subway, train, or high-speed train, the brake disc all directly influences the driving safety of these vehicles. Conventional brake discs are made of cast steel and cast iron materials. But the brake disc is heavy due to cast steel and cast iron materials. For example, a subway train with a six-car consist has 48 brake discs, the weight of which is about 3.6 tons, while a high-speed train has 16 brake discs in the car compartment and 12 brake discs in the trailer compartment, so that the high-speed train with the 16-car consist has 224 brake discs, the weight of which reaches forty more tons. The method is an obvious potential for digging the railway vehicle when the railway vehicle pursues self light weight, transportation heavy load, energy utilization efficiency improvement and emission pollution reduction. Therefore, many professionals in relevant units at home and abroad begin to research on aluminum-based alloy brake discs. The reason for this is that the cast iron cast steel material has a density of 7.8g/cm3And the density of the aluminum alloy is 2.8g/cm3The weight of the steel is almost one third of that of cast steel and cast iron, and obviously, the steel is a very important potential for saving energy and improving efficiency for traffic vehicles which seek to lighten weight.
At present, manufacturers of aluminum alloy brake discs with relatively mature application are German Knorr companies which are known as profound industries, and the developed aluminum alloy brake discs are adopted in the multi-country subway industry. Several research units and professional manufacturers are also in research, development and trial production in China. At present, the production process technology adopted by the aluminum-based alloy brake disc mainly comprises the following steps: stirring casting, pressure casting and the latest generation of powder metallurgy technology production in trial production. However, although the aluminum-based alloy can meet the requirements of the brake disc in terms of strength, the aluminum-based alloy has low wear resistance, large wear and easy occurrence of 'furrow' wear phenomenon, so that the problems in popularization and use are temporarily and fashionably not solved, the aluminum-based alloy cannot well meet the requirements of large-area popularization and application of the brake disc of the railway vehicle, and particularly traffic vehicles with the speed of more than 120Km/hr cannot be applied.
SUMMERY OF THE UTILITY MODEL
The utility model provides an aluminum-based alloy brake disc with a wear-resistant coating, aiming at the problem that although the aluminum-based alloy brake disc in the prior art can meet the requirement of light weight of a vehicle, the aluminum-based alloy brake disc has low wear resistance. The purpose of the utility model is realized by the following technical scheme:
the aluminum-based alloy brake disc with the wear-resistant coating comprises an aluminum-based alloy brake disc base body and is characterized in that a wear-resistant alloy layer is sprayed on the surface of the aluminum-based alloy brake disc base body, the aluminum-based alloy brake disc base body adopts a national standard 7075T651 alloy, the bonding strength of the wear-resistant alloy layer and the aluminum-based alloy brake disc base body is larger than or equal to 70MPa, and the thickness of the wear-resistant alloy layer is 0.2-0.5 mm.
The aluminum-based alloy brake disc with the wear-resistant coating can meet the requirement of light weight, the specific gravity of the brake disc is small (2.8g/cm3), the super wear-resistant alloy layer can meet the wear resistance required by the brake disc, and meanwhile, due to the existence of the super wear-resistant layer, the brake block of the brake friction pair formed by the super wear-resistant alloy layer can be made of powder metallurgy brake materials, so that the brake safety performance of a vehicle can be ensured more easily. The utility model solves the problems of heavy weight and energy waste of the existing cast steel and cast iron material brake disc, overcomes the defects of non-wear resistance and the like of the latest aluminum-based alloy brake disc, perfectly unifies light weight and high wear resistance, and provides a brand-new and advanced brake disc for the railway vehicle. Can fully meet the requirements of various vehicles, and has low temperature rise, low noise and long service life when braking.
Drawings
FIG. 1 is a schematic structural view of an aluminum-based alloy brake disc with a wear-resistant coating provided in the present embodiment;
FIG. 2 is a flow chart for manufacturing the aluminum-based alloy brake disc with the wear-resistant coating according to the embodiment;
FIG. 3 is a flow chart of a manufacturing process of the aluminum-based alloy brake disc base body with the wear-resistant coating according to the embodiment;
in the figure: 1-an aluminum-based alloy brake disc matrix and 2-a wear-resistant coating.
Detailed Description
The utility model will be further described with reference to the accompanying drawings, but the scope of the utility model is not limited to the following.
Example 1:
the embodiment provides an aluminum-based alloy brake disc with a wear-resistant coating, which comprises an aluminum-based alloy brake disc substrate, wherein a wear-resistant alloy layer is sprayed on the surface of the aluminum-based alloy brake disc substrate.
The wear-resistant alloy layer comprises the following raw materials in parts by weight:
the component A comprises: WC;
and B component: ni: 71.25, Cr: 15. mo: 2.5, Fe: 4.3, C: 0.45, B: 2.3, Si: 4.2;
A. the mixing proportion of the component B is as follows: a: 32, B: 68.
the wear resistant layer is suitable for powder metallurgy brake pads.
The aluminum-based alloy brake disc base body adopts a national standard 7075T651 alloy, and the physical properties of the base body material are as follows: hardness HB157, tensile strength 570 MPa.
The manufacturing process of the aluminum-based alloy brake disc with the wear-resistant coating comprises the following process steps:
(1) manufacturing an aluminum-based alloy brake disc substrate by adopting a high-strength aluminum alloy plate machining process or a pressure casting process;
(2) carrying out sand blasting and roughening treatment on the surface of the aluminum-based alloy brake disc substrate pre-coated with the wear-resistant coating;
(3) the method comprises the following steps of setting powdery wear-resistant alloy coating raw materials, wherein the granularity of the raw materials is within the range of 100-300 meshes, and the wear-resistant alloy layer comprises the following raw materials in parts by weight:
the component A comprises: WC;
and B component: ni: 71.25, Cr: 15. mo: 2.5, Fe: 4.3, C: 0.45, B: 2.3, Si: 4.2;
A. the mixing proportion of the component B is as follows: a: 32, B: 68;
(4) mixing raw materials of a wear-resistant alloy coating, loading the mixed raw material powder of the wear-resistant layer into plasma spray welding equipment or supersonic spray gun equipment, uniformly spraying the powder of the mixed raw material powder of the wear-resistant layer on the surface of an aluminum-based alloy brake disc substrate to form a wear-resistant alloy coating, wherein the bonding strength between the wear-resistant alloy layer and the aluminum-based alloy brake disc substrate is more than or equal to 70MPa, spraying the wear-resistant material on the aluminum-based alloy brake disc substrate at a high speed through the plasma spray equipment or the supersonic spray equipment, enabling the powder to be in a molten state in the spraying process, bonding the powder into a compact layer under the action of high-speed impact, and enabling the thickness of the wear-resistant alloy coating to be 0.2-0.5 mm;
(5) grinding the surface of the wear-resistant layer of the sprayed aluminum-based alloy brake disc with the wear-resistant coating to form a rough surface, wherein the surface roughness is as follows: ra0.8-1.6.
(6) And carrying out dynamic balance adjustment to ensure that the brake disc has good dynamic balance performance during operation, and avoiding the vibration phenomenon caused by the good dynamic balance performance.
(7) Quality inspection: including the performance indexes of the product such as geometric shape, the bonding strength of the wear-resistant layer and the matrix, the matrix strength, the hardness, the wear-resistant layer hardness and the like.
The embodiment provides an aluminum-based alloy brake disc with a wear-resistant coating, and the performance parameters are as follows:
powder metallurgy brake pads were used in the tests. The test carries out simulation emergency braking and simulation operation condition braking according to the relevant requirements that the speed is not more than 200Km/h in the technical conditions of temporary brake lining of the motor train unit TJCL 307-2019.
Raising the temperature to 131-192 ℃;
the friction coefficient is 0.37-0.41;
the hardness of the wear-resistant layer is HV 740;
the bonding strength of the matrix and the wear-resistant layer is 82 MPa.
Example 2:
the embodiment provides an aluminum-based alloy brake disc with a wear-resistant coating, which comprises an aluminum-based alloy brake disc base body, wherein a wear-resistant alloy layer is sprayed on the surface of the aluminum-based alloy brake disc base body.
The wear-resistant alloy layer comprises the following raw materials in parts by weight:
the component A comprises: WC;
and B component: ni: 39. cr: 25. mo: 9. fe: 2. c: 0.3, B: 2.1, Si: 1.6;
A. the mixing proportion of the component B is as follows: a: 32, B: 68.
the wear resistant layer is suitable for powder metallurgy brake pads.
The aluminum-based alloy brake disc base body adopts a national standard 7075T651 alloy, and the physical properties of the base body material are as follows: hardness HB157, tensile strength 570 MPa.
The manufacturing process of the aluminum-based alloy brake disc with the wear-resistant coating is characterized by comprising the following process steps:
(1) manufacturing an aluminum-based alloy brake disc substrate by adopting a high-strength aluminum alloy plate machining process or a pressure casting process;
(2) carrying out sand blasting and roughening treatment on the surface of the aluminum-based alloy brake disc substrate pre-coated with the wear-resistant coating;
(3) the method comprises the following steps of setting powdery wear-resistant alloy coating raw materials, wherein the granularity of the raw materials is within the range of 100-300 meshes, and the wear-resistant alloy layer comprises the following raw materials in parts by weight:
the component A comprises: WC;
and B component: ni: 39. cr: 25. mo: 9. fe: 2. c: 0.3, B: 2.1, Si: 1.6;
A. the mixing proportion of the component B is as follows: a: 32, B: 68;
(4) mixing raw materials of a wear-resistant alloy coating, loading the mixed raw material powder of the wear-resistant layer into plasma spray welding equipment or supersonic spray gun equipment, uniformly spraying the powder of the mixed raw material powder of the wear-resistant layer on the surface of an aluminum-based alloy brake disc substrate to form a wear-resistant alloy coating, wherein the bonding strength between the wear-resistant alloy layer and the aluminum-based alloy brake disc substrate is more than or equal to 70MPa, spraying the wear-resistant material on the aluminum-based alloy brake disc substrate at a high speed through the plasma spray equipment or the supersonic spray equipment, enabling the powder to be in a molten state in the spraying process, bonding the powder into a compact layer under the action of high-speed impact, and enabling the thickness of the wear-resistant alloy coating to be 0.2-0.5 mm;
(5) grinding the surface of the wear-resistant layer of the sprayed aluminum-based alloy brake disc with the wear-resistant coating to form a rough surface, wherein the surface roughness is as follows: ra0.8-1.6.
(6) And carrying out dynamic balance adjustment to ensure that the brake disc has good dynamic balance performance during operation, and avoiding the vibration phenomenon caused by the good dynamic balance performance.
(7) Quality inspection: the method comprises the performance indexes of the product such as the geometric shape, the bonding strength of the wear-resistant layer and the matrix, the matrix strength, the hardness, the wear-resistant layer hardness and the like.
The embodiment provides an aluminum-based alloy brake disc with a wear-resistant coating, which has the following performance parameters:
powder metallurgy brake pads were used in the tests. The test carries out simulation emergency braking and simulation operation condition braking according to the relevant requirements that the speed is not more than 200Km/h in the technical conditions of temporary brake lining of the motor train unit TJCL 307-2019.
Raising the temperature to 131-192 ℃;
the friction coefficient is 0.37-0.41;
the hardness of the wear-resistant layer is HV 761;
the bonding strength of the matrix and the wear-resistant layer is 83 MPa.
Example 3:
the embodiment provides an aluminum-based alloy brake disc with a wear-resistant coating, which comprises an aluminum-based alloy brake disc substrate, wherein a wear-resistant alloy layer is sprayed on the surface of the aluminum-based alloy brake disc substrate.
The wear-resistant alloy layer comprises the following raw materials in parts by weight:
the component A comprises: WC;
and B component: ni: 51. cr: 15. mo: 4. fe: 3. c: 0.6, B: 2.1, Si: 6;
A. the mixing proportion of the component B is as follows: a: 31, B: 69.
the wear resistant layer is suitable for powder metallurgy brake pads.
The aluminum-based alloy brake disc base body adopts a national standard 7075T651 alloy, and the physical properties of the base body material are as follows: hardness HB157, tensile strength 570 MPa.
The manufacturing process of the aluminum-based alloy brake disc with the wear-resistant coating is characterized by comprising the following process steps of:
(1) manufacturing an aluminum-based alloy brake disc substrate by adopting a high-strength aluminum alloy plate machining process or a pressure casting process;
(2) carrying out sand blasting and roughening treatment on the surface of the aluminum-based alloy brake disc substrate pre-coated with the wear-resistant coating;
(3) the method comprises the following steps of setting powdery wear-resistant alloy coating raw materials, wherein the granularity of the raw materials is within the range of 100-300 meshes, and the wear-resistant alloy layer comprises the following raw materials in parts by weight:
the component A comprises: WC;
and B component: ni: 51. cr: 15. mo: 4. fe: 3. c: 0.6, B: 2.1, Si: 6;
A. the mixing proportion of the component B is as follows: a: 31, B: 69;
(4) mixing raw materials of a wear-resistant alloy coating, filling the mixed raw powder of the wear-resistant layer into plasma spray welding equipment or supersonic spray gun equipment, uniformly spraying the surface of an aluminum-based alloy brake disc substrate to form a wear-resistant alloy coating, wherein the bonding strength of the wear-resistant alloy layer and the aluminum-based alloy brake disc substrate is more than or equal to 70Mpa, spraying the wear-resistant material on the aluminum-based alloy brake disc substrate at a high speed through the plasma spray equipment or the supersonic spray equipment, melting the powder in a spraying process, bonding the powder into a compact layer under the action of high-speed impact, and forming the thickness of the wear-resistant alloy coating to be 0.2-0.5 mm;
(5) grinding the surface of the wear-resistant layer of the sprayed aluminum-based alloy brake disc with the wear-resistant coating to form a rough surface, wherein the surface roughness is as follows: ra0.8-1.6.
(6) And carrying out dynamic balance adjustment to ensure that the brake disc has good dynamic balance performance during operation, and avoiding the vibration phenomenon caused by the good dynamic balance performance.
(7) Quality inspection: including the performance indexes of the product such as geometric shape, the bonding strength of the wear-resistant layer and the matrix, the matrix strength, the hardness, the wear-resistant layer hardness and the like.
The embodiment provides an aluminum-based alloy brake disc with a wear-resistant coating, and the performance parameters are as follows:
powder metallurgy brake pads were used in the tests. The test carries out simulation emergency braking and simulation operation condition braking according to the relevant requirements that the speed is not more than 200Km/h in the technical conditions of temporary brake lining of the motor train unit TJCL 307-2019.
Raising the temperature to 131-192 ℃;
the friction coefficient is 0.37-0.41;
the hardness of the wear-resistant layer is HV 750;
the bonding strength of the base body and the wear-resistant layer is 83 MPa.
The aluminum-based alloy brake disc can meet the lightweight requirement of the brake disc, the specific gravity of the brake disc is small (2.8g/cm3), the super wear-resistant alloy layer can meet the wear resistance required by the brake disc, and meanwhile, due to the existence of the super wear-resistant layer, the brake block forming a brake friction pair with the super wear-resistant alloy layer can be made of powder metallurgy brake materials, so that the brake safety performance of a vehicle can be ensured more easily. The utility model solves the problems of heavy weight and energy waste of the existing cast steel and cast iron material brake disc, overcomes the defects of non-wear resistance and the like of the latest aluminum-based alloy brake disc, perfectly unifies light weight and high wear resistance, and provides a brand-new and advanced brake disc for the railway vehicle. Can fully meet the requirements of various vehicles, and has low temperature rise, low noise and long service life when braking. And the braking safety performance of the vehicle is easier to ensure, the pollution is reduced, and the vehicle is not influenced by the moisture, water, low temperature and the like in the environment.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the utility model, the scope of which is defined in the appended claims and their equivalents.
Claims (1)
1. The aluminum-based alloy brake disc with the wear-resistant coating for the rail vehicle comprises an aluminum-based alloy brake disc base body and is characterized in that the aluminum-based alloy brake disc base body adopts a national standard 7075T651 alloy, a wear-resistant alloy layer is sprayed on the surface of the aluminum-based alloy brake disc base body, the bonding strength between the wear-resistant alloy layer and the aluminum-based alloy brake disc base body is not less than 70MPa, the thickness of the wear-resistant alloy layer is 0.2-0.5 mm, a rough surface is formed on the surface of the wear-resistant alloy layer, and the roughness is as follows: ra0.8-1.6.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115011906A (en) * | 2022-05-18 | 2022-09-06 | 淄博国创中心先进车用材料技术创新中心 | Wear-resistant aluminum alloy brake disc and preparation method thereof |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115011906A (en) * | 2022-05-18 | 2022-09-06 | 淄博国创中心先进车用材料技术创新中心 | Wear-resistant aluminum alloy brake disc and preparation method thereof |
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Address after: 050000 No. 18 Huangshan street, Shijiazhuang circular chemical industry park, Hebei Province Patentee after: Shijiazhuang Taiwei Technology Co.,Ltd. Address before: 050000 No.18 Huangshan street, East Development Zone, Shijiazhuang City, Hebei Province Patentee before: SHIJIAZHUANG GLOBAL NEW CENTURY TOOLS CO.,LTD. |
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