WO1995009251A1 - Composites a matrice metallique - Google Patents

Composites a matrice metallique Download PDF

Info

Publication number
WO1995009251A1
WO1995009251A1 PCT/GB1994/002119 GB9402119W WO9509251A1 WO 1995009251 A1 WO1995009251 A1 WO 1995009251A1 GB 9402119 W GB9402119 W GB 9402119W WO 9509251 A1 WO9509251 A1 WO 9509251A1
Authority
WO
WIPO (PCT)
Prior art keywords
porous member
component
work surface
infiltration
component according
Prior art date
Application number
PCT/GB1994/002119
Other languages
English (en)
Inventor
Richard Arnold Bass
Original Assignee
Automotive Products Plc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Automotive Products Plc filed Critical Automotive Products Plc
Priority to GB9509358A priority Critical patent/GB2287038A/en
Publication of WO1995009251A1 publication Critical patent/WO1995009251A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • 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
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • 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
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/127—Discs; Drums for disc brakes characterised by properties of the disc surface; Discs lined with friction material
    • 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
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D2055/0004—Parts or details of disc brakes
    • F16D2055/0016—Brake calipers
    • 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
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/04—Attachment of linings
    • F16D2069/0425—Attachment methods or devices
    • F16D2069/0491—Tools, machines, processes
    • 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
    • F16D2200/006—Materials; Production methods therefor containing fibres or particles

Definitions

  • This invention relates to metal matrix composites i.e. materials comprising a metal phase reinforced with a disperse phase which may or may not be a metal.
  • a typical metal matrix composite comprises aluminium with 10% to 40% by volume of silicon carbide or aluminium oxide dispersed therein.
  • Such materials have a wide variety of uses where wear resistance, lightness, stiffness and strength are important.
  • such materials are used to manufacture vehicle brake components such as brake discs and calipers .
  • a metal matrix composite component having a work surface formed on a porous member infiltrated with a metal - containing infiltrate.
  • the percentage of infiltration in the porous member decreases towards the work surface.
  • the infiltrate will be aluminium with or without fibre reinforcement.
  • the variation in percentage infiltration can be produced by using a porous member of non-uniform cross-sectional density with the work surface portion of the porous member having a higher cross-sectional density to give lower percentage infiltration than the remainder of the porous member .
  • a porous member of substantially uniform cross-sectional density can be used and the percentage infiltration controlled by controlling the operating conditions under which the infiltration process occurs.
  • the entire component may be formed from a porous member with a low or zero percentage metal infiltration in a high density work surface portion of the member and a high percentage metal infiltration in a main low density structural portion of the member spaced from the work surface.
  • an infiltrated porous member may provide the work surface, the porous member being bonded onto a structural portion.
  • the structural portion may comprise an MMC containing silicon carbide or aluminium oxide in particulate form in an aluminium matrix.
  • the porous member is preferably formed from silicon carbide or aluminium oxide and any variation in density across the cross section leading to the work surface is produced using settling or cent i using techniques.
  • a component in accordance with the present invention is particularly suitable for use as a brake disc with two spaced work surfaces for engagement by brake pads and a structural portion therebetween.
  • ком ⁇ онент in accordance with the present invention include brake calipers, clutch pressure plates and vehicle flywheels.
  • the present invention also provides a method of manufacturing a metal matrix composite component comprisin : -
  • the porous member is infiltrated non-uniformly with the percentage of infiltration decreasing towards said work surface where very low or substantially zero infiltration occurs.
  • the porous member may be formed into the desired final shape of the component so that the entire component is made from infiltrated porous material.
  • a porous member which is to provide the work surface in the finished component may be placed in a mould defining the finished shape of the component to partially fill said mould, and a metal matrix composite in liquid form may be poured into the mould to fill the mould and infiltrate the porous member.
  • Fig 1 is a diagrammatic radial half-section through a first form of brake disc in accordance with the present invention
  • Figs 2a and 2b show diagrammaticaliy an alternative two-peice porous member construction for the brake disc of figure 1, figure 2b being a view on the arrow'A" of figure 2a;
  • Fig 3 is a diagrammatic radial half-section through a second form of brake disc in accordance with the invention
  • Fig 4 is a diagrammatic radial half-section through part of a mould used in one method of manufacture of the brake disc of figure 3.
  • a brake disc 10 which may be of solid or ventilated form, has work or friction surfaces 11 and 12 designed to be contacted by brake pads 13.
  • a radial inner flange portion 14 of the brake disc is provided with a series of circumferentially spaced apertures 15 through which fastening bolts extend to bolt the disc to a rotating portion of an associated vehicle wheel hub.
  • the brake disc 10 is formed from an annular ceramic porous member 16, which is typically silicon carbide or aluminium oxide, and which is infiltrated by aluminium.
  • the density of the porous member is designed to vary being least dense in its central portion y and most dense in its work surface portion x.
  • This porous member of varying cross-sectional density is typically produced from a viscous slurry of ceramic particles by allowing the slurry to settle or by assisting settling using centrifuging techniques.
  • the resulting settled/centrifuged slurry is then formed to the required shape using for example, hot or cold isostatic pressing in which the material is pressed to shape by a confining mould. Alternatively, injection moulding techniques can be used.
  • the production of the porous member is completed by a sintering process.
  • the porous member is infiltrated by a metal, typically aluminium, which due to the non-uniform cross-sectional density of the porous member achieves a high infiltration in the central (and thus structural) portion of the disc and a low or zero penetration in the work surface portion x of the disc.
  • the work surface portion x will be 0.25 mm thick and have almost zero aluminium infiltration so that there is little or no exposure of the aluminium matrix to the effects of the operating environment of the disc .
  • the density of the porous member IB may be as low as 10% so that there is an extremely high (90%) infiltration by aluminium giving the necessary strength to the disc.
  • the high density in the work surface portion x of the porous member 16 not only insulates the aluminium from the outside operating environment but also insulates the central structural portion of the disc from the high temperatures, typically up to 800 degrees centigrade which arise at the work surface of the disc.
  • the porous member and/or the infiltrate can be reinforced with fibres, eg carbon fibres, which may be in chopped form.
  • the porous member 16 may be in one piece or, as shown in figures 2a and 2b, may be in two or more pieces 16a, 16b which may or may not have circumferentialiy spaced castellations or other interengaging formations 17,18 to assist in unifying the two pieces and render the pieces less likely to rotate relative to each other under brakin .
  • pieces 16a and 16b When using this type of two-piece construction, pieces 16a and 16b have a high density in the vacinity of work surfaces 11a, lib and a low density in the vacinity of castellated inner surfaces 17 and 18 . This simplifies the production of a complete porous member with low density in its control portion ?n ⁇ i high density at its work surface portions .
  • non-uniform cross-sectional density to control the percentage infiltration of the porous member it is possible to use a porous member of substantially uniform cross-sectional density and to control the percentage infiltration of this member by controlling the operating conditions under which the infiltration process is carried out. For example, the time for which and pressure under which the infiltrate is applied may be varied so that portions of the porous member more remote from the infiltration source receive less infiltrate. Alternatively, or additionally, a masking technique can be used where portions of the porous member are masked to reduce infiltration.
  • Figure 3 shows an alternative brake disc construction in which the disc 20 has work surfaces 21 and 22 which are designed to be contacted by pads 23.
  • the work surfaces 21 and 22 are provided on annular porous members 24 and 25 which are again typically formed from silicon carbide or aluminium oxide (using the viscous slurry, settling/centrifugin , pressing and sintering technique described above) and which may or may not be fibre reinforced.
  • the porous members have a thickness of 2 to 3 mm and a non-uniform cross sectional density. It will be appreciated that the thickness of the porous members may be a greater of lesser proportion of the total thickness of the disc depending on the intended use to which the disc is to be put.
  • the work surfaces 21 and 22 have a cross sectional density of approximately 100% and at the inner surfaces 26 and 27 have a cross-sectional density of the order of 10%.
  • the main structural portion 28 of the disc is formed from a particulate MMC which is moulded in liquid form (typically aluminium containing silicon carbide particles or aluminium oxide) .
  • the liquid MMC infiltrates into the porous members 24 and 25 during moulding to produce high infiltration percentage at the boundary 26,27 with the porous member and low or zero infiltration at the working surfaces 21 and 22.
  • the infiltrate can be reinforced with fibres which may be in chopped form.
  • porous members 24 and 25 can be of uniform cross-sectional density and the percentage infiltration comtrolled by control of the operating conditions of the infiltration process as described above in relation to porous member 16.
  • Fig 4 shows a section through part of a mould 30 used in the manufacture of the brake disc 20 shown in Fig 3.
  • the mould 30 has two main parts 31 and 32 and an outer annular part 33.
  • Porous members 21 and 22 are held in place by shoulders 33a on mould part 33 and by one or more support members 34 formed from aluminium which are absorbed into the MMC during the moulding process. Any other suitable means for locating porous members 21 and 22 in the mould during the moulding process may be used.
  • the liquid particulate MMC material is poured into the mould through one of more inlets 35 in mould part 33 to fill the space between the porous members 21 and 22 and also to infiltrate into these members as described above.
  • the invention is also applicable to the manufacture of brake calipers.
  • those portions of a caiiper which are contacted by the brake pads could benefit from having their work surfaces provided by a porous member infiltration in accordance with the present invention ⁇ _o provide better wear resistance and increased insulation against the passage of heat from the pads r_o the caiiper.
  • the or each caiiper piston bore could benefit from being formed from a porous member infiltration in accordance with the present invention to insulate against the effects of heat.
  • Vehicle flywheels and clutch pressure plates are also further examples of components which would benefit from manufacture from the porous member infiltration of the present invention.
  • Such a flywheel would have a work surface for contact by a clutch friction member and such a clutch pressure plate would have two work surfaces, one to be contacted by a clutch friction member (where the heat insulating capabilities of the present invention would predominate) and the other to be contact by a clutch operating cover or diaphragm spring (where wear resistance is of more concern) .
  • the present invention is applicable to a wide range of other metals and disperse materials.
  • metals and disperse materials for example, in addition to aluminium, magnesium and titanium, or alloys based on these three metals, may be used and disperse materials such as carbon and boron carbide are also suitable.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Braking Arrangements (AREA)

Abstract

L'invention se rapporte à un composant à base de composite à matrice métallique, tel qu'un disque de frein, doté d'une surface de travail formée sur un élément poreux infiltré avec un matériau d'infiltration métallique. En général, l'élément poreux est formé à partir de carbure de silicium ou d'oxyde d'aluminium et le matériau d'infiltration contient de l'aluminium à très faible pouvoir ou à pouvoir sensiblement nul d'infiltration de la surface de travail. L'invention se rapporte également à des procédés de fabrication de tels composants à base de ce composite.
PCT/GB1994/002119 1993-09-30 1994-09-29 Composites a matrice metallique WO1995009251A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9509358A GB2287038A (en) 1993-09-30 1994-09-29 Metal matrix composites

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9320150.7 1993-09-30
GB939320150A GB9320150D0 (en) 1993-09-30 1993-09-30 Metal matrix composite components

Publications (1)

Publication Number Publication Date
WO1995009251A1 true WO1995009251A1 (fr) 1995-04-06

Family

ID=10742753

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1994/002119 WO1995009251A1 (fr) 1993-09-30 1994-09-29 Composites a matrice metallique

Country Status (2)

Country Link
GB (1) GB9320150D0 (fr)
WO (1) WO1995009251A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0846884A3 (fr) * 1996-12-03 1998-07-01 Thyssen Guss Ag Procédé de fabrication d'un disque de frein, en particulier d'un disque de freind'arbre ou de roue pour véhicules de chemin de fer.
WO2010131273A1 (fr) * 2009-05-13 2010-11-18 Freni Brembo S. .A. Procédé de fabrication d'un composant pour système de freinage et composant pour système de freinage
US20120186919A1 (en) * 2011-01-26 2012-07-26 GM Global Technology Operations LLC Molded Components Having a Visible Designer Feature and/or Improved Operational Properties via a Porous Preform

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS62185845A (ja) * 1986-02-10 1987-08-14 Nissan Motor Co Ltd 複合材料
EP0250210A2 (fr) * 1986-06-17 1987-12-23 The Regents Of The University Of California Procédé de fabrication de matériaux composites métallo-céramiques et matériaux composites ainsi obtenus
GB2219537A (en) * 1988-05-11 1989-12-13 Hitachi Ltd Member having improved surface layer and process for making the same
EP0386556A2 (fr) * 1989-03-04 1990-09-12 Fried. Krupp AG Procédé pour la production d'un composite métallique qui a une région présentant une résistance élevée à l'usure
EP0410284A2 (fr) * 1989-07-22 1991-01-30 Osaka Fuji Corporation Matériau composite céramique-métal
US5024899A (en) * 1990-10-22 1991-06-18 Lang Richard D Resilient metallic friction facing material
EP0446934A2 (fr) * 1990-03-15 1991-09-18 Kabushiki Kaisha Toshiba Procédé pour la fabrication de matériau composite, et matériau thermoconducteur et procédé pour la fabrication de ce matériau thermoconducteur
EP0452275A1 (fr) * 1990-04-12 1991-10-16 Battelle Memorial Institute Méthode pour produire des articles d'un matériau avec un gradient fonctionnel
WO1992019782A1 (fr) * 1991-04-29 1992-11-12 Lanxide Technology Company, Lp Corps composites a proprietes graduelles et procedes de fabrication desdits corps

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS62185845A (ja) * 1986-02-10 1987-08-14 Nissan Motor Co Ltd 複合材料
EP0250210A2 (fr) * 1986-06-17 1987-12-23 The Regents Of The University Of California Procédé de fabrication de matériaux composites métallo-céramiques et matériaux composites ainsi obtenus
GB2219537A (en) * 1988-05-11 1989-12-13 Hitachi Ltd Member having improved surface layer and process for making the same
EP0386556A2 (fr) * 1989-03-04 1990-09-12 Fried. Krupp AG Procédé pour la production d'un composite métallique qui a une région présentant une résistance élevée à l'usure
EP0410284A2 (fr) * 1989-07-22 1991-01-30 Osaka Fuji Corporation Matériau composite céramique-métal
EP0446934A2 (fr) * 1990-03-15 1991-09-18 Kabushiki Kaisha Toshiba Procédé pour la fabrication de matériau composite, et matériau thermoconducteur et procédé pour la fabrication de ce matériau thermoconducteur
EP0452275A1 (fr) * 1990-04-12 1991-10-16 Battelle Memorial Institute Méthode pour produire des articles d'un matériau avec un gradient fonctionnel
US5024899A (en) * 1990-10-22 1991-06-18 Lang Richard D Resilient metallic friction facing material
WO1992019782A1 (fr) * 1991-04-29 1992-11-12 Lanxide Technology Company, Lp Corps composites a proprietes graduelles et procedes de fabrication desdits corps

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 12, no. 37 (C - 473) 4 February 1988 (1988-02-04) *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0846884A3 (fr) * 1996-12-03 1998-07-01 Thyssen Guss Ag Procédé de fabrication d'un disque de frein, en particulier d'un disque de freind'arbre ou de roue pour véhicules de chemin de fer.
EP1500841A3 (fr) * 1996-12-03 2005-02-09 SAB WABCO GmbH Procédé de fabrication d'un disque de frein, en particulier d'un disque de frein d'arbre ou de roue pour véhicules de chemin de fer
WO2010131273A1 (fr) * 2009-05-13 2010-11-18 Freni Brembo S. .A. Procédé de fabrication d'un composant pour système de freinage et composant pour système de freinage
US20120186919A1 (en) * 2011-01-26 2012-07-26 GM Global Technology Operations LLC Molded Components Having a Visible Designer Feature and/or Improved Operational Properties via a Porous Preform

Also Published As

Publication number Publication date
GB9320150D0 (en) 1993-11-17

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