KR101893990B1 - Method for manufacturing aluminium brake disc and the aluminum break disk obtained in accordance with the said method - Google Patents
Method for manufacturing aluminium brake disc and the aluminum break disk obtained in accordance with the said method Download PDFInfo
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- KR101893990B1 KR101893990B1 KR1020160000831A KR20160000831A KR101893990B1 KR 101893990 B1 KR101893990 B1 KR 101893990B1 KR 1020160000831 A KR1020160000831 A KR 1020160000831A KR 20160000831 A KR20160000831 A KR 20160000831A KR 101893990 B1 KR101893990 B1 KR 101893990B1
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- aluminum
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- alloy
- disk
- intermediate layer
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/123—Spraying molten metal
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
- F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0004—Materials; Production methods therefor metallic
- F16D2200/0026—Non-ferro
- F16D2200/003—Light metals, e.g. aluminium
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2250/00—Manufacturing; Assembly
- F16D2250/0038—Surface treatment
- F16D2250/0046—Coating
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
- Braking Arrangements (AREA)
Abstract
The present invention relates to a method for manufacturing a magnetic recording medium, comprising the steps of: coating a surface of an aluminum (Al) disk with nickel (Ni) or a nickel-aluminum (Ni-Al) alloy by spray coating to form an intermediate layer; And coating an iron-based alloy on the upper portion of the intermediate layer by a spraying method. The present invention also provides an aluminum brake disk and a method of manufacturing the aluminum brake disk.
Description
The present invention relates to a method of manufacturing an aluminum brake disk and an aluminum brake disk implemented by the method, and more particularly, to a method of manufacturing a lightweight aluminum brake disk and an aluminum brake disk implemented by the method.
Generally, braking of an automobile is mainly performed by a friction between a circular disk mounted on an axle and a caliper. However, due to the friction between the brake disc and the pad in the caliper, the temperature of the brake disc rises rapidly to about 500 ° C or more, thereby reducing the frictional force with the caliper and causing a fade phenomenon in which the braking performance is reduced. In addition, the performance and strength of the brake disc are deteriorated, the service life is shortened, the braking distance of the vehicle is increased, and the brake device is ruptured, thus increasing the risk of accidents.
In recent years, aluminum brake discs have been researched in place of conventional gray cast iron wheels in accordance with the tendency to lighten automobiles. The friction surface of the aluminum material is coated with a material having a weak wear resistance and a high wear resistance, or alloyed with the above material to manufacture a brake disc. However, the manufacturing cost is high and the manufacturing process is complicated. Further, there is a problem that a crack is formed on the joint surface of the lightweight brake disc and the wear-resistant material.
Disclosure of Invention Technical Problem [8] Accordingly, the present invention has been made to solve the above-mentioned problems, and it is an object of the present invention to provide an aluminum brake disk having improved friction force on a friction surface of a disk, The purpose. However, these problems are exemplary and do not limit the scope of the present invention.
According to one aspect of the present invention, there is provided a method of manufacturing an aluminum brake disk. The method for manufacturing an aluminum brake disk includes coating an aluminum (Al) disk surface with nickel (Ni) or a nickel-aluminum (Ni-Al) alloy by spray coating to form an intermediate layer; And coating an iron-based alloy on the upper part of the intermediate layer by a spraying method.
In the method for manufacturing an aluminum brake disk, the nickel-aluminum alloy may include a nickel-chromium-aluminum-yttrium (Ni-Cr-Al-Y) alloy powder or a wire.
In the method for manufacturing an aluminum brake disk, the iron-based alloy may include an iron-carbon (Fe-C) alloy powder or a wire.
In the method for manufacturing the aluminum brake disk, the spraying method may include any one of plasma spraying, cold gas spraying, and arc spraying.
In the method for manufacturing an aluminum brake disk, in the step of forming the intermediate layer, the spraying method may be coated with plasma spraying at 25V to 35V, 90A to 110A and a coating distance of 170 mm to 190 mm.
In the method of manufacturing the aluminum brake disk, in the step of coating the iron-based alloy, the spraying method may be coated with arc spraying at 90V to 110V, 400A to 500A and coating distance of 150 mm to 250 mm.
In the aluminum brake disk manufacturing method, the coefficient of thermal expansion (CTE) of the intermediate layer may have a value of 12.5 to 14.5.
Wherein the nickel-aluminum alloy is a nickel-chromium-aluminum-yttrium alloy powder, the size of the powder is 15 to 63 탆, and the surface of the aluminum disk is coated with a plasma spraying method The intermediate layer can be formed.
In the method for manufacturing the aluminum brake disk, the iron-based alloy is an iron-carbon (Fe-C) alloy wire, the diameter of the wire is 1.5 to 2.5, and the upper part of the intermediate layer is coated by arc spraying.
According to another aspect of the present invention, there is provided an aluminum brake disk. The aluminum brake disk is produced by coating an aluminum (Al) disk surface with nickel (Ni) or a nickel-aluminum (Ni-Al) alloy by spray coating to form an intermediate layer, By coating, the hardness and wear amount of 260 Hv to 280 Hv may have a wear amount of more than 0 and less than 2 cm 3.
According to an embodiment of the present invention as described above, a method of manufacturing an aluminum brake disk having a low risk of breakage, excellent heat dissipation performance, and light weight, and an aluminum brake disk realized by the method can be realized. Of course, the scope of the present invention is not limited by these effects.
1 is a process flow diagram schematically illustrating a method of manufacturing an aluminum brake disk according to an embodiment of the present invention.
2 is an exploded perspective view schematically showing a structure of an aluminum brake disk according to an embodiment of the present invention.
Figs. 3 and 4 are the results of analysis of the joint surfaces of aluminum brake disk samples according to the examples and comparative examples of the present invention by scanning electron microscopy.
FIG. 5 is a result of composition mapping of a joint surface of an aluminum brake disk sample according to an embodiment of the present invention.
6 shows the results of measurement of hardness and abrasion of an aluminum brake disk sample according to Examples and Comparative Examples of the present invention.
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be understood, however, that the invention is not limited to the disclosed embodiments, but may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, Is provided to fully inform the user. Also, for convenience of explanation, the components may be exaggerated or reduced in size.
1 is a process flow diagram schematically illustrating a method of manufacturing an aluminum brake disk according to an embodiment of the present invention.
Referring to FIG. 1, a method of manufacturing an aluminum brake disk according to an embodiment of the present invention includes spraying a nickel (Ni) or nickel-aluminum (Ni-Al) alloy on the surface of an aluminum (S100) of forming an intermediate layer by coating, and coating (S200) coating an iron-based alloy by spraying on the intermediate layer.
The nickel-aluminum alloy may include, for example, a Ni-5Al alloy or a nickel-chromium-aluminum-yttrium (Ni-Cr-Al-Y) alloy, and may be in the form of powder or wire. And any other nickel-aluminum alloy material having a thermal expansion coefficient value located between the coefficient of thermal expansion of the wear-resistant material and the coefficient of thermal expansion of the aluminum brake disk.
Here, the intermediate layer containing the nickel or nickel-aluminum alloy may have an intermediate value of the thermal expansion coefficient values of the iron-based alloy coating layer and the aluminum alloy disk. The value of the coefficient of thermal expansion of the iron-based alloy coating layer located on the uppermost layer is smaller than the value of the coefficient of thermal expansion of the aluminum alloy. If the coefficient of thermal expansion of the intermediate layer is smaller than the coefficient of thermal expansion of the iron-based alloy coating layer, the thermal shock can not be mitigated and the adhesive strength may be lowered or cracks may occur.
The coefficient of thermal expansion (CTE) of the intermediate layer has a value of 12.5 to 14.5. Generally, the coefficient of thermal expansion of the aluminum alloy base material has a value of 19.4 to 23.4, and in the case of the wear resistant layer, that is, the iron-based alloy coating layer, the coefficient of thermal expansion has a value of 10.1 to 11.7. Therefore, a material having a coefficient of thermal expansion of between 11.7 and 19.4 can be used as the intermediate layer. However, it is preferable to use a material having a value of 12.5 to 14.5 so as to smoothly perform the function of mitigating the thermal shock.
Further, the iron-based alloy may include, for example, an iron-carbon (Fe-C) alloy powder or a wire. Here, the iron-based alloy can be understood as an iron-based alloy having a relatively large gray iron or friction coefficient. In addition to the above alloy powder, alloys of the same type as wire can be used.
The spraying method may include any one of plasma spraying, cold gas spraying and arc spraying. In the step of forming the intermediate layer (S100) and the step of coating the iron-based alloy (S200), the type of the thermal spraying method and the processing conditions may be different depending on the material to be coated. In order to simplify the process and simplify the manufacturing process, Can be performed.
Details of the structure and manufacturing method of the aluminum brake disc will be described later with reference to FIGS. 2 to 6. FIG.
2 is an exploded perspective view schematically showing a structure of a brake according to an embodiment of the present invention.
Referring to FIG. 2, an aluminum brake disk according to an embodiment of the present invention may include a
Technologies such as ABS or VDS / ESP have been developed to stabilize the vehicle through braking. At this time, if the braking is repeatedly used, the drum brake having the disadvantage of not being braked due to the expansion is not applied. In recent years, the disc type has been used for the rear wheel as well as the front wheel. The disk type is referred to as a disk brake. The
The
For example, the step of forming the intermediate layer (S100) may be performed by a plasma spraying method under conditions of about 25V to 35V, 90A to 110A, and coating distance (distance between gun and base material) Or a nickel-aluminum alloy. Here, the process conditions of the plasma spraying are process conditions which can be used when coating a nickel-chromium-aluminum-yttrium (Ni-Cr-Al-Y) alloy powder, and it is preferable that the kind and shape of the disk base material and the nickel- Can be different.
The step of coating the iron-based alloy (S200) may be performed by an arc spraying method under the process conditions of about 90 V to 110 V, 400 A to 500 A, and a coating distance (distance between the base materials) of 150 mm to 250 mm. . ≪ / RTI > Here, the processing conditions of the arc spraying may be different depending on the kind and the form of the intermediate layer and the iron-based alloy, which can be used in coating the iron-carbon (Fe-C) alloy wire.
In addition, the spraying method may include any one of plasma spraying, cold gas spraying, and arc spraying. Here, the coating may be performed under different process conditions for each step of forming the intermediate layer and coating of the iron-based alloy, but the same spraying process and the same process conditions may be used for the convenience of the process and shortening the manufacturing time. In addition, the spraying method can be replaced in various ways depending on the material of the powder to be coated, the size of the particles, and the shape of the coating material (powder, wire, etc.).
In summary, an intermediate layer is formed by coating nickel (Ni) or nickel-aluminum (Ni-Al) alloy on the surface of an aluminum (Al) disk by spray coating, and an iron- , An aluminum brake disk having a hardness of 260 Hv to 280 Hv and a wear amount of less than 2 cm < 3 > can be realized. Here, the nickel-aluminum alloy is a nickel-chromium-aluminum-yttrium alloy powder, the size of the powder particles is 15 to 63 탆, and the intermediate layer can be formed by coating the surface of the aluminum disk with a plasma spraying method . The iron-based alloy is an iron-carbon (Fe-C) alloy wire. The diameter of the wire is 1.5 to 2.5, and the upper part of the intermediate layer is coated with an arc spraying method.
In addition, since the iron-based alloy coating layer, which is the uppermost layer of the aluminum disk and the aluminum disk, has different materials, the contraction ratio may be different and cracks may occur. The intermediate layer can solve the problem that cracks or voids are formed due to thermal shock due to frictional heat at the interface between the aluminum disk and the iron-based alloy coating layer. In addition, in order to improve the braking ability of each surface rubbed by the caliper, that is, the iron-based alloy coating layer, it is necessary to keep the friction surfaces parallel to each other.
On the other hand, when the
Further, when the
Hereinafter, an experimental example to which the technical idea described above is applied will be described in order to facilitate understanding of the present invention. It should be understood, however, that the following examples are for the purpose of promoting understanding of the present invention and are not intended to limit the scope of the present invention.
As a sample according to the experimental example of the present invention, a disk made of aluminum was formed. Then, a Ni-Cr-Al-Y alloy powder having a particle size of about 15 mu m to 63 mu m was coated on the surface of the aluminum disk by plasma spraying under the process conditions of 30 V, 100 A and dry distance of 180 mm. Then, an aluminum brake disk sample was prepared by coating an Fe-C alloy wire having a diameter of about 2? On the Ni-Cr-Al-Y alloy coating layer by arc spraying under the conditions of 100 V, 450 A and a gun distance of 200 mm. Thereafter, the bonded surfaces of the aluminum brake disk samples produced were analyzed by a scanning electron microscope.
On the other hand, for comparison, an aluminum brake disk sample of a comparative example was prepared by directly forming an Fe-C alloy layer on the surface of an aluminum disk without forming a Ni-Cr-Al-Y alloy coating layer in the above embodiment. Cracks on the joint surface were observed in the same manner as in the above Experimental Example using the above comparative sample.
FIGS. 3 and 4 are the results of analysis of bonding surfaces of aluminum brake disk samples according to Examples and Comparative Examples of the present invention by a scanning electron microscope, As a result of composition mapping.
Referring to FIGS. 3 to 5, cracks or voids are generated on the joint surfaces of the
6 shows the results of measurement of hardness and abrasion of an aluminum brake disk sample according to Examples and Comparative Examples of the present invention.
Referring to FIG. 6, Vickers hardness and wear test results of an aluminum brake disk sample according to an embodiment of the present invention and a comparative example are shown. The abrasion test was conducted on a pin-on-disc method under the conditions of a counter material SKD11, a load of 10 kgf, a speed of 60 rpm, and a time of 120 seconds. The wear amount was obtained by converting the worn weight into the volume.
The
As described above, a lightweight aluminum brake disk can be manufactured by coating an abrasion-resistant material, that is, an iron-based alloy (Fe-C alloy powder), on a friction surface of a brake disk made of an aluminum material by a spraying method. Aluminum and iron-based alloys have a problem of poor adhesion due to the difference in thermal expansion coefficient. A nickel-aluminum alloy layer is first formed as an intermediate layer by a spraying method before coating the iron-based alloy, thereby preventing cracks and damage of the brake disk due to the difference in thermal expansion coefficient. Accordingly, it is possible to provide a method of manufacturing an aluminum brake disk for automobile which can extend the service life of the brake disk by improving the bonding force between the aluminum brake disk and the wear-resistant layer, and is light and excellent in performance.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention. Accordingly, the true scope of the present invention should be determined by the technical idea of the appended claims.
100, 110: Brake disk
200: Brake pad
Claims (10)
Coating an iron-based alloy on the upper portion of the intermediate layer by spraying;
Lt; / RTI >
Wherein the nickel-aluminum alloy is a nickel-chromium-aluminum-yttrium (Ni-Cr-Al-Y) alloy powder and the surface of the aluminum disk is coated with a plasma spraying method to form the intermediate layer,
Wherein the iron-based alloy is an iron-carbon (Fe-C) alloy wire, the diameter of the wire is 1.5 to 2.5, and the upper part of the intermediate layer is coated with an arc-
Wherein the intermediate layer has a value of a coefficient of thermal expansion (CTE) value of the iron-based alloy and the disk,
Wherein the intermediate layer has a coefficient of thermal expansion of 12.5 to 14.5,
A method of manufacturing an aluminum brake disk.
In the step of forming the intermediate layer, the spraying method may be performed by coating a plasma spray with 25V to 35V, 90A to 110A and a coating distance of 170 mm to 190 mm,
A method of manufacturing an aluminum brake disk.
In the step of coating the iron-based alloy, the spraying method is applied by arc spraying at 90V to 110V, 400A to 500A and a coating distance of 150 mm to 250 mm.
A method of manufacturing an aluminum brake disk.
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KR1020160000831A KR101893990B1 (en) | 2016-01-05 | 2016-01-05 | Method for manufacturing aluminium brake disc and the aluminum break disk obtained in accordance with the said method |
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KR1020160000831A KR101893990B1 (en) | 2016-01-05 | 2016-01-05 | Method for manufacturing aluminium brake disc and the aluminum break disk obtained in accordance with the said method |
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KR20170081863A KR20170081863A (en) | 2017-07-13 |
KR101893990B1 true KR101893990B1 (en) | 2018-08-31 |
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Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP3679444B2 (en) | 1994-03-25 | 2005-08-03 | ジエ・ウー・セー・アルストム・トランスポール・エス・アー | Composite disc for high energy braking |
US20110151140A1 (en) | 2009-12-21 | 2011-06-23 | Brian Thomas Hazel | Methods Of Forming Nickel Aluminde Coatings |
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JP3262365B2 (en) * | 1992-03-19 | 2002-03-04 | 三井金属鉱業株式会社 | Manufacturing method of brake disc |
JPH08145092A (en) * | 1994-11-17 | 1996-06-04 | Yoshino Giken Kk | Disc rotor |
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Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
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JP3679444B2 (en) | 1994-03-25 | 2005-08-03 | ジエ・ウー・セー・アルストム・トランスポール・エス・アー | Composite disc for high energy braking |
US20110151140A1 (en) | 2009-12-21 | 2011-06-23 | Brian Thomas Hazel | Methods Of Forming Nickel Aluminde Coatings |
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