WO2015169024A1

WO2015169024A1 - Friction disk of metal/continuous-structure phase ceramic composite material and method for manufacturing same

Info

Publication number: WO2015169024A1
Application number: PCT/CN2014/086942
Authority: WO
Inventors: 房殊
Original assignee: 房殊
Priority date: 2014-05-09
Filing date: 2014-09-19
Publication date: 2015-11-12
Also published as: CN104235237B; CN106536963A; CN104235237A

Abstract

A friction disc of metal/continuous-structure phase ceramic composite material and a method for manufacturing same are provided. The friction disc comprises a metal disc body (1) and a friction layer of metal/continuous-structure phase ceramic composite material arranged on one side or symmetrically arranged on both sides of the disc body. The metal disc body (1) is a metal backboard mechanically connected with the friction layer (3); or the metal disc body can be made of the same material as the composite material in the friction layer (3), and integrally cast with the friction layer; or the metal disc body can be made of the same material as the metal material in the friction layer (3) and integrally cast with the friction layer; or the metal disc body can be made of the same material as the metal material in the friction layer (3) and integrally cast with the friction layer, the disc body having reinforcing ribs. The friction disc of composite material can significantly reduce the weight of clutch plates and friction braking plates, and also has excellent friction and wear performance. It can not only carry out safe and effective friction clutch and brake operation for various kinds of rotating machinery, but also achieve the purpose of reducing cost, light weight and energy saving.

Description

Metal/continuous structural phase ceramic composite friction disc and manufacturing method thereof

Technical field

The invention relates to a metal/continuous structural phase ceramic composite friction disc and a manufacturing method thereof. The friction disc is a clutch disc and a brake disc of a road traffic vehicle, a rail transit vehicle, an airplane, a ship and other rotary motion machines.

Background technique

With the increasing energy shortage in the world, lightweight technologies aimed at saving energy, reducing weight and reducing costs have begun to attract attention. At present, most of the road traffic vehicles, rail transit vehicles, airplanes, ships, rotary motion mechanical clutch plates, friction brake discs still use metal materials, the main disadvantage is that the density is large, which is not conducive to weight reduction; Friction surface temperature rises too high during friction and braking; temperature gradient is large, stress concentration is concentrated, hot spots are formed, and hot cracks are generated; carbon/carbon brake discs are expensive; all of these are unfavorable factors affecting their use. .

Low cost and light weight are not only requirements for road traffic vehicles, rail transit vehicles, airplanes, ships, clutch plates for rotating sports machinery, friction brake discs, but also for road traffic vehicles, rail transit vehicles, airplanes, ships, rotary motion machines. One of the key technologies that need to be solved in the clutch plate and friction brake disc. Ceramic reinforced metal, especially silicon carbide ceramic and metal material composite, prepared into road traffic vehicles, rail transit vehicles, aircraft, ships, rotary motion machinery metal / continuous structural phase ceramic composite clutch plates, friction brake discs, Not only can the weight of the clutch plate and the friction brake disc be significantly reduced, the cost and weight can be reduced, and the noise and temperature rise of the clutch plate and the friction brake disk during friction and braking can be greatly reduced, and the thermal crack caused by thermal stress can be reduced. Improve the wear resistance and life of clutch plates and friction brake discs. As road traffic vehicles, rail transit vehicles, airplanes, ships, rotary motion machines, etc. continue to develop in the direction of high speed and heavy load, the bonding strength to the ceramic reinforced metal composite interface, the shape of the ceramic reinforcement, and the ceramic reinforcement are enhanced. A number of factors that directly affect the properties of metal/ceramic composites, such as uniformity in metals, also place higher demands.

In order to meet the higher requirements for the development of clutch plates and friction brake discs in highway vehicles, rail transit vehicles, airplanes, ships, rotary motion machines, etc., the world is using carbon/carbon and carbon. /Tao, metal/ceramic composites have done a lot of work in place of traditional clutch plates and friction brake discs. Ceramic reinforced metal composites have become one of the research priorities due to their low cost. The ceramic reinforcing phase mainly includes particles, fibers, whiskers and continuous structural phase ceramic preforms. Among them, ceramic particles, fiber and whisker reinforcement are the most studied enhancement methods, but they form a discontinuous structure phase when combined with metal, which is easy to cause ceramic particles, fibers and whisker reinforced metal/ceramic composites to appear during use. Bonding off reduces the performance of the composite. Continuous structure phase ceramic reinforced metal/ceramic composite material is a research hotspot in recent years. It is also difficult to prepare large size when the ceramic reinforced metal/ceramic composite materials such as particles, fibers and whiskers are solved. An important means of profiled metal/ceramic composite parts.

Compared with traditional steel materials, metal/ceramic composites, especially aluminum alloy/ceramic composites, have attracted light in various countries due to their light weight, high specific strength, specific stiffness and good thermal stability and wear resistance. The field is deeply engaged in the development of aluminum alloy/ceramic composite materials. However, these studies and inventions have focused on the reinforcement of aluminum alloy composites using particles, whiskers, fibers, and the like. In recent years, there have been many reports on the use of ceramic particles, whiskers, fibers and discontinuous structures for the production of brake discs for aluminum-based composites. For example, patents US6536564, US 5,576,667, US 6,854,089, patent CN03127145, patent CN 200610137913, patents CN 201220269503, patent CN201310593025.2, patent CN 201310008726.5, patent CN201310008715.7 and the like. However, the methods described in these patents have the following disadvantages in varying degrees: the particles and whiskers are easily agglomerated during the preparation of the composite; the physical and chemical properties of the continuous or discontinuous fiber reinforcement and the matrix alloy are different in physical and chemical properties. Larger, it is difficult to be uniformly combined with the base metal material; it is difficult to prepare a friction layer with a thickness of 5-10 mm on the surface of the aluminum-based brake disc by laser cladding, ion spraying, etc., which seriously affects the mechanics of the brake disc. Performance and use.

In order to overcome the shortcomings of the above-mentioned ceramic particles, fibers and whisker-reinforced metal/ceramic composite clutch plates and brake disc patents, attempts have been made to reinforce metals with continuous structural phase ceramics. Among them, a three-dimensional network structure reinforced metal matrix composites (3DNSRMMCs) has attracted great attention from the industry. The composite material has special topological geometric characteristics, and the reinforcing phase and the matrix body are entangled, coiled, interpenetrated and composited to form a new material which is completely unified and relatively independent, and forms a transition layer at the interface between the ceramic and the metal. 3DNSRMMCs have the advantages of light weight, high specific modulus, high specific strength, fatigue resistance, thermal shock resistance and low thermal expansion coefficient. They have shown good performance in the fields of aerospace, transportation, machinery manufacturing, especially in the field of friction materials. Application prospects.

At present, there are many methods for preparing foam-structured ceramic skeleton reinforcements, such as a foaming method, a sol-gel method, a self-propagating high-temperature synthesis method, and an organic precursor ablation-sintering method. Among them, the organic precursor ablation-sintering method is the most simple and effective method for preparing foam structural ceramic reinforcement. At the same time, there are many methods for preparing 3DNSRMMCs composite materials, such as powder metallurgy (PM), stirred casting (SC), in situ reaction (In situ), high temperature self-propagation (SHS), thermal diffusion reaction (XDTM). And melt infiltration (MITM) and the like. The melt infiltration technique is one of the main methods for preparing 3DNSRMMCs composite materials. According to the different melt impregnation dynamics, the melt infiltration technology is divided into three categories: PRIMEXTM, pressure infiltration (PIM) and vacuum infiltration (VDI).

In general, the preparation of 3DNSRMMCs composite materials, especially the combination of steel materials and ceramic skeletons, has three main problems in the preparation of 3DNSRMMCs composite materials:

1 The two phases of the reinforcement and the metal should not be completely independent of each other, and the interaction between them should be reduced, and the complete chemical reaction can not occur, and the reinforcing effect is deteriorated. Therefore, it is necessary to modify the surface of the foam structure reinforcement to obtain the best. Composite interface Microstructures, and existing studies generally lack research on pretreatment of their surfaces.

2 Vacuum infiltration and pressure infiltration technology have high production cost, complicated process and equipment, and it is difficult to prepare high-quality heat-treated large-size castings to achieve low-cost industrial production.

3 Pressureless infiltration technology is difficult to overcome the surface tension of the foam ceramic skeleton due to insufficient pressure, and can not produce high-quality large-size castings, or the product contains a large number of casting defects such as shrinkage, shrinkage, looseness, cold insulation and insufficient pouring.

Summary of the invention

The technical problem to be solved by the present invention is to provide a small quality, a short production cycle, a fast heat dissipation, and a good thermal stability for the characteristics of friction wheels for different road traffic vehicles, rail transit vehicles, airplanes, ships, and rotary motion machines. A metal/continuous structural phase ceramic composite friction disc with long service life and small deformation.

Furthermore, the present invention provides a method for manufacturing a metal/continuous structural phase ceramic composite friction disk, which has the advantages of smooth friction braking, low noise, long service life and convenient disassembly.

In order to achieve the above object, the friction disc of the present invention is realized by the following technical solutions:

The friction disc of the present invention comprises a metal disc body and a metal/continuous structural phase ceramic composite friction layer disposed on one side of the metal disc body or symmetrically disposed on both sides thereof; the metal disc body is a metal mechanically connected to the friction layer The backing plate is formed of a composite material which is the same as the friction layer composite material and is integrally cast with the friction layer; or is formed of a metal material which is the same as the metal material in the friction layer and is integrally cast with the friction layer; or It is formed of a metal material which is made of the same material as the metal material in the friction layer and which is integrally cast with the friction layer and has a reinforcing rib.

Further, the mechanical connection between the metal backing plate and the friction layer of the present invention means: riveting, welding or bolting.

Further, the reinforcing rib of the present invention is disposed along the radial direction of the non-friction surface of the friction disc and integrally molded with the friction layer, and the reinforcing rib is in a straight line or a curved shape.

Further, the shape of the reinforcing rib of the present invention is one of a lath, a cylinder, an elliptical cylinder, a T-shape, and an I-shape.

Further, the friction disk of the present invention is provided with a vent hole, and the vent hole includes a radial vent hole disposed along a radial direction of the disk body and/or an axial vent hole disposed along the axial direction of the disk body; The venting hole is formed by a hole penetrating through or not penetrating the disk of the friction disk, and the outline thereof is circular, elliptical, rectangular or hexagonal; when the friction disk has a symmetrical friction layer, the radial vent hole is rubbed a straight line in the circumferential direction of the disk non-friction surface or a hole between the curved reinforcing ribs; or, when the friction disk has a friction layer, the radial vent hole is in the circumferential direction of the non-friction surface of the two friction disks a hole formed between the straight or curved reinforcing ribs; or, when the friction disc has a friction layer, the radial venting holes are straight or curved reinforcing ribs and other metal disc bodies in the circumferential direction of the non-friction surface of the friction disc The formed holes are formed. The venting holes can be integrally cast on the friction disc.

Further, the radial direction of the friction layer of the present invention may be integrally cast with a ventilation groove; the ventilation groove is linear or curved in the radial direction.

Further, the friction disc of the present invention is integrally molded with a mounting hole or a block for connecting with a rotating disc or a rotating shaft of the moving component; the contour of the mounting hole or the block may be a circle, an ellipse or a rectangle. Or hexagonal.

Further, the continuous structural phase ceramic of the present invention is a continuous structural phase ceramic skeleton; the continuous structural phase ceramic skeleton in the friction layer accounts for 5 to 60% by volume of the friction layer; and the thickness is 2 to 35 mm.

Further, the continuous structural phase ceramic skeleton of the present invention is classified into: a silicon carbide ceramic skeleton, a silicon nitride ceramic skeleton, an alumina ceramic skeleton, a zirconia ceramic skeleton, a mullite ceramic skeleton, or a silicon carbide according to different materials; a composite ceramic skeleton of silicon nitride, aluminum oxide or zirconium oxide;

Corresponding silicon carbide, silicon nitride, aluminum oxide, zirconium oxide, mullite in the continuous structural phase ceramic skeleton; or silicon carbide, silicon nitride, aluminum oxide, zirconia multiphase ceramics as a percentage of the total mass of the ceramic skeleton It is 60 to 99% by weight.

Further, the structure of the continuous structural phase ceramic skeleton of the present invention is a periodic laminated structure, a planar lattice structure, a continuous columnar structure or a three-dimensional network continuous structure; wherein the periodic laminated structure ceramic skeleton is an octahedron, a hexahedron, a tetrahedron a stack of quadrangular pyramids, fullerenes, or other structures having round, elliptical, rectangular, hexagonal, or other geometric shapes; the holes in the planar grid structure ceramic skeleton are circles, ellipses, rectangles, and hexagons , triangular or other geometric shape, the number of grids per square centimeter is 1 to 15; the cross section of the pillar in the continuous columnar ceramic skeleton is circular, elliptical, rhombic, rectangular, hexagonal, triangular or other geometric shape; The three-dimensional network continuous structure ceramic skeleton is interconnected in a three-dimensional direction, the porosity is 40 to 90%, and the mesh diameter is 0.5 to 8 mm.

Further, the material of the metal material in the metal disk body and the metal/continuous structure phase ceramic composite material of the friction disk of the present invention is: aluminum alloy, magnesium alloy, titanium alloy, high temperature alloy, copper alloy, iron or steel.

Further, the aluminum alloy of the present invention is a ZLXXX, 7XXX, 6XXX, 5XXX, 4XXX, 2XXX or 1XXX series aluminum alloy.

Further, the aluminum alloy, the magnesium alloy, the titanium alloy, the high-temperature alloy, the copper alloy, the iron or the steel of the present invention may have a one-dimensional or two-dimensional shape with an average particle diameter of 20 to 100 nm and a volume percentage of the metal of 0.1 to 5%. The carbon material is strengthened and toughened, and the one-dimensional or two-dimensional carbon material is carbon nanotube or graphene; or, the nano-ceramic having an average particle diameter of 20 to 500 nm and a volume percentage of the metal of 0.1 to 5% may be used. The particles are strengthened and toughened, and the nano ceramic particles are silicon carbide, titanium carbide, titanium carbonitride, aluminum oxide, copper oxide or silicon oxide.

Further, the casting method used in the production of the friction disc of the present invention is atmospheric casting, low pressure casting, pressure casting, negative pressure casting, differential pressure casting or vacuum-pressure casting; or the above casting method is combined with electromagnetic field or combined with ultrasonic wave. At the time of manufacture, the molten metal is cast into a cavity in which the ceramic skeleton of the continuous structure phase is fixed, and the integrated metal/join is obtained. The friction disc of the friction layer of the structural phase ceramic composite material; or the frictional layer of the integrally cast metal/continuous structural phase ceramic composite material friction layer and the metal back sheet is mechanically obtained to obtain a friction disc; and then obtained by precision machining or heat treatment + precision machining The finished friction disc.

Further, the manufacturing method of the ceramic skeleton in the friction disc of the present invention is: template grouting method, precursor impregnation method, gel injection molding method, foaming method, adding pore-forming agent method, sol-gel method, freeze-drying method Method, dry pressing forming method, isostatic pressing forming method or three-dimensional printing method; in the production, the ceramic skeleton blank body is first prepared, and then the reaction sintering, pressureless sintering or hot pressing sintering method is adopted, and the sintering is 10 to 300 mm long and wide. 10 to 300 mm, ceramic frame with a thickness of 2 to 35 mm; silicon carbide, silicon nitride, aluminum oxide, zirconia, mullite, or silicon carbide, silicon nitride, aluminum oxide, zirconia multiphase ceramics The percentage of the total mass is 60 to 99 wt%, and the balance is a sintering aid or a sintered addition phase, and the sintering aid or the sintering addition phase is selected from the group consisting of boron carbide, carbon, silicon oxide, aluminum oxide, cerium oxide, silicon nitride, and Titanium boride, zirconium diboride or molybdenum disilicide.

Further, the surface of the continuous structural phase ceramic skeleton of the present invention may be pretreated, if the pretreatment method is as follows: the continuous structural phase ceramic skeleton is placed in an oxidizing atmosphere furnace at 800 to 950 ° C, and the temperature is maintained for 0.5 to 12 hours to obtain a a layer of oxide film of 20 to 500 μm; or a layer of carbon or graphite made of carbon nanotubes, petroleum coke, carbon black, conductive carbon paste, printing ink or graphite on the surface of the continuous structural phase ceramic skeleton The material is dried to obtain a carbon or graphite layer having a thickness of 20 to 500 μm; or the surface of the continuous structural phase ceramic skeleton is chemically or electrochemically coated to cover a surface of a chromium oxide having a thickness of 20 to 500 μm. A film of cerium oxide, titanium oxide, rare earth oxide, alkaline earth oxide or metal Ni, Cu, Ti, Cr.

Further, the casting mold used in the method for manufacturing the metal/continuous structural phase ceramic composite friction disc of the present invention has a disk shape, and includes an upper mold, a lower mold and a gate provided on the mold; a positioning groove and a positioning block for preventing movement and drift of the ceramic skeleton are disposed in the cavity; the upper die is provided with a ejector rod for preventing movement and drift of the ceramic skeleton; and a friction disk having ventilation holes between the integrally cast symmetric friction layers The casting mold further includes a sand core, and the upper half of the sand core is provided with a positioning block capable of preventing the ceramic skeleton from moving and drifting; the lower half of the sand core is provided to prevent the ceramic skeleton from moving and drifting The ram of the casting mold has the same shape as the ceramic skeleton of the continuous structure phase; the positioning block and the ejector may have a circular, elliptical, rectangular or hexagonal cross section.

The friction disc is a road traffic vehicle, a rail transit vehicle, an airplane, a ship, a clutch plate for a rotary motion machine, or a friction brake disc.

The rib of the invention has the functions of reinforcing the disc body and increasing heat dissipation.

The friction disk of the present invention is integrally cast by mechanical connection or mold. When integrally casting, the position of the ceramic skeleton of the continuous structure phase is preset in the mold, and the module for forming the reinforcing rib, the ventilation groove, the ventilation hole, the mounting hole or the block is preset, and after the ceramic skeleton of the continuous structure phase is placed, the metal material is cast. .

The non-friction surface of the friction disc according to the present invention is a surface layer on the friction disc that is not provided with a friction layer, and corresponds to the other side of the friction layer.

The metal disk body of the present invention is a mechanically connected metal back plate or is the same as the composite material in the friction layer or is made of the same material as the metal material in the friction layer, and is integrally cast with the friction layer and has a reinforcing rib. The metal material is formed. Specifically, when the metal disk body is manufactured, the position of the reinforcing rib is preset in the casting mold, or the sand core is placed in the mold, and then integrally cast into a metal disk body with a reinforcing rib.

The beneficial effects produced by the above technical solutions are:

1 The composite friction disc prepared by the invention can significantly reduce the weight of the clutch plate and the friction brake disc, and can reduce the weight by 20 to 60% compared with the conventional clutch disc and the friction brake disc. In addition, it has excellent friction and wear performance, not only can implement safe and effective friction clutching and braking for all kinds of high-speed, heavy-duty road traffic vehicles, rail transit vehicles, aircrafts, rotating machinery, but also achieve low cost and light weight. The purpose and requirements of energy saving and weight reduction.

2 The invention uses low pressure casting, pressure casting and vacuum-pressure casting process to realize continuous and industrial production of large aluminum alloy/continuous structural phase ceramic composite clutch plates and friction brake discs. The short production cycle greatly reduces production costs. The pressure solidification process in low pressure casting and pressure casting can strengthen the shrinkage ability of aluminum alloy during crystallization, greatly improve the density of castings, and ensure the strength, macroscopic structure and microscopic display of aluminum alloy/continuous structural phase ceramic composites. The uniformity of the microstructure.

3 The friction layer of the metal/continuous structural phase ceramic composite in the friction disc makes full use of the advantages of good thermal conductivity, good toughness, high temperature strength and wear resistance of the ceramic material, and obtains better heat decay resistance. During the braking process, the ceramic skeleton forms hard microprotrusions and acts as a load bearing, inhibiting plastic deformation and high temperature softening of the metal, especially the aluminum alloy, and improving the thermal fatigue resistance.

4 The carbon layer covered by the ceramic skeleton surface can be used as a lubricating component to adjust the friction coefficient and reduce the braking noise. During the long-term service, a solid and stable friction mechanical layer is formed on the friction surface of the brake disc, which significantly improves the high-temperature friction and wear performance of the composite material. The surface active layer covering the surface of the ceramic skeleton can improve the wetting ability of the ceramic skeleton and the metal matrix, and improve the interface strength of the ceramic/metal.

5 The surface treatment of the ceramic skeleton of the invention solves the problem of wetting of ceramics and metals, especially aluminum alloys, so that the reinforcement has good wettability with the metal matrix, the interface has a slight chemical reaction, and has good, An interfacial transition layer of moderate thickness for optimal reinforcement.

6 The metal/continuous structural phase ceramic composite friction disc produced by the method of the invention optimizes the structure and performance, reduces the thermal stress of the brake disc, thermal damage and the temperature of the friction surface during braking, and can effectively avoid the occurrence of the conventional Friction discs of metal materials and cracks and crack propagation in non-continuous structural ceramic phase reinforced aluminum alloy friction discs such as granules, whiskers and fibers.

7 The metal/continuous structural phase ceramic composite friction disc produced by the method of the invention has wide application range, and can be combined with all materials and types of brake shoes, such as powder metallurgy, semi-metal, synthetic resin and non-asbestos organic. Pair of friction and brake shoes such as fiber ceramic brake pads (NAO).

DRAWINGS

1-1 is a schematic structural diagram of Embodiment 1 of the present invention;

1-2 is a side view of the first embodiment of the present invention;

Figure 1-3 is a cross-sectional view taken along line A-A of Figure 1-2;

Figure 2 is a schematic view of a silicon carbide foam ceramic skeleton cut into a desired shape;

Figure 3 is a microscopic structure of a ceramic skeleton under different pretreatments;

Wherein: 3A is the microstructure of the ceramic skeleton pretreated by the oxidizing atmosphere coating in Example 4;

3B is the microstructure of the ceramic skeleton after electroplating pretreatment in Example 3;

3C is the microstructure of the ceramic skeleton after spray coating pretreatment in Example 1;

3D is the microstructure of the ceramic skeleton without pretreatment;

Figure 4 is a macroscopic structural photograph of the interface between the silicon carbide foam ceramic and the aluminum alloy after T6 heat treatment;

Figure 5 is the microstructure of the brake disc body ZL111 aluminum alloy material;

Figure 6-1 is a graph showing the temperature and friction coefficient of the friction disc produced in Example 1 under different conditions;

6-2 is a graph showing the temperature and friction coefficient of the friction disc prepared in Example 1 under different conditions;

7-1 is a schematic structural view of Embodiment 2 of the present invention;

7-2 is a schematic left side view of Embodiment 2 of the present invention;

7-3 is a right side view of Embodiment 2 of the present invention;

7-4 is a schematic perspective view of a second embodiment of the present invention;

8 is a test data of a subway friction disk according to Embodiment 2 of the present invention;

9-1 is an experimental result of a friction coefficient of a subway friction disc under different speeds and pressures according to Embodiment 2 of the present invention;

9-2 is an experimental result of temperature rise of a subway friction disk during heavy energy continuous braking according to Embodiment 2 of the present invention;

9-3 is a test result of a friction coefficient of a large frictional braking of a subway friction disk according to Embodiment 2 of the present invention;

10-1 is a schematic structural view of Embodiment 3 of the present invention;

10-2 is a schematic rear view of Embodiment 3 of the present invention;

Figure 10-3 is a cross-sectional view taken along line B-B of Figure 10-2;

10-4 is a schematic perspective view of a third embodiment of the present invention;

11-1 is a test data of a high-iron friction disk according to Embodiment 3 of the present invention;

11-2 is a test data of a high-iron friction disk according to Embodiment 3 of the present invention;

12-1 is an experimental result of a friction coefficient under different speed and pressure conditions of a high-iron friction disk according to Embodiment 3 of the present invention;

12-2 is an experimental result of a friction coefficient of different speeds, pressures, and water sprays of a high-iron friction disk according to Embodiment 3 of the present invention;

13-1 is a schematic structural view of an aircraft moving plate according to Embodiment 4 of the present invention;

13-2 is a cross-sectional view showing an aircraft moving plate according to Embodiment 4 of the present invention;

13-3 is a schematic structural view of an aircraft stationary plate according to Embodiment 4 of the present invention;

13-4 is a cross-sectional view showing a stationary disk of an aircraft according to Embodiment 4 of the present invention;

14-1 is a test data diagram of a friction disk produced in Example 4 of the present invention;

Figure 14-2 is a test data diagram of the friction disk produced in Example 4 of the present invention;

Figure 15-1 is a schematic structural view of a clutch plate according to Embodiment 5 of the present invention;

Figure 15-2 is a cross-sectional view showing the clutch plate of Embodiment 5 of the present invention;

16 is a schematic structural view of a ceramic frame of a periodic laminated structure according to Embodiment 6 of the present invention;

17 is a schematic structural view of a ceramic frame of a planar grid structure according to Embodiment 7 of the present invention;

18 is a schematic structural view of a ceramic column of a continuous columnar structure according to Embodiment 8 of the present invention;

19-1 is a schematic structural view of a lower mold according to Embodiment 10 of the present invention;

19-2 is a schematic structural view of an upper mold according to Embodiment 10 of the present invention;

20-1 is a schematic structural view of a sand core according to Embodiment 10 of the present invention;

20-2 is a side elevational view of a sand core according to Embodiment 10 of the present invention.

In the drawing, 1 metal disk body, 2 continuous structure phase ceramic skeleton, 3 friction layer, 4 ventilation slots, 5-1 radial ventilation holes, 5-2 axial ventilation holes, 6 reinforcing ribs, 7 mounting holes, 8 Cross pin hole, 9 card block, 10 positioning block, 11 positioning groove, 12 ejector pin, 13 sand core, 14 ceramic frame groove.

detailed description

The material used for the composite material friction disc of the road traffic vehicle and the composite material of the subway brake disc and the high-speed iron brake disc is ZLXXX, 7XXX, 6XXX, 5XXX, 4XXX, 2XXX or 1XXX series aluminum alloy. The metal plate of the composite disc for the composite brake disc of the invention is made of steel, and the static disc of the brake disc is made of copper alloy.

The friction disc or the brake disc is integrally cast with a silicon carbide foam ceramic skeleton, and the ceramic skeleton accounts for 10 to 50 vol.% of the friction layer of the composite material; the ceramic skeleton cast in the brake disc has a thickness of 5 to 15 mm. The friction layer can be integrally cast with ventilation slots and axial vents and radial vents.

Mounting holes are evenly distributed on the disc body of the friction disc or brake disc of the automobile, the subway and the high-speed rail, and the disc body is non-friction A plurality of geometrically combined reinforcing ribs are cast in the circumferential direction of the face, and radial venting holes are formed between the ribs and the ribs or the ribs and the other faces.

The brake disc body for the aircraft is evenly distributed with fixed moving discs and static discs to prevent the rotating blocks.

Example 1

The structure of the silicon carbide foam ceramic skeleton reinforced ZL111 composite brake disc cast in this embodiment is as shown in FIGS. 1-1, 1-2, and 1-3, and the friction disc includes a metal disc body 1 and is symmetrically disposed on the metal. Metal/continuous structural phase ceramic composite friction layer 3 on both sides of the disk body 1. The friction layer 3 is formed of a continuous structural phase ceramic skeleton 2 integrally cast in a metal. The structure of the continuous structural phase ceramic skeleton 2 is as shown in FIG. The metal disk body 1 is a metal material which is the same as the metal material in the friction layer 3 and is integrally cast with the friction layer 3, and the friction disk is integrally cast with a reinforcing rib 6 and a ventilation groove 4, the reinforcing rib 6 is a metal material which is the same as the material of the metal material in the friction layer 3 and is integrally cast with the friction layer 3 . The rib 6 is a curved shape disposed in a radial direction of the non-friction surface of the friction disk. The friction disc of the present embodiment has a symmetrical friction layer 3, and the gap between the ribs 6 on the friction disc forms a radial vent 5-1. The metal disk body 1 is evenly distributed with mounting holes 7.

The manufacturing process of the silicon carbide foam ceramic skeleton reinforced ZL111 composite brake disc is as follows:

Preparation:

Step 1: Preparation of a three-dimensional grid silicon carbide ceramic skeleton: using a precursor impregnation method, the mass percentage of silicon carbide in the silicon carbide foam ceramic skeleton is 90 to 99%, and the balance is a ratio of boron carbide to carbon. The slurry was prepared by using a polyurethane foam precursor of 8-15 ppi as a template to prepare a silicon carbide ceramic green body and drying. The silicon carbide ceramic green body is placed in a sintering furnace at 1950 to 2280 ° C for 0.5 to 3 hours, and a silicon carbide ceramic block having a length of 400 mm, a width of 400 mm, and a thickness of 5 to 15 mm is obtained by pressureless sintering, and is cut into A shape (see Fig. 2) is required as a reinforcement of the friction layer. The silicon carbide foam ceramic has a porosity of 40 to 60% and a mesh diameter of 1.5 to 4 mm. The ceramic skeleton has a bulk density of 2.6 to 3.2/cm ³ , a Vickers hardness (Hv) of 30 GPa, a flexural strength of 0.5 to 15 MPa, a compressive strength of 1.5 to 20 MPa, and a thermal conductivity of 80 to 100 W/(m·K).

As an optimization scheme, a certain amount of titanium diboride (TiB ₂ ), or Ti ₃ SiC ₂ , or zirconium diboride (ZrB ₂ ), or molybdenum disilicide (MoSi ₂ ) ceramics may be added to the silicon carbide slurry. One or more of them to increase the sintering and lubricating ability of the silicon carbide skeleton, wherein the silicon carbide accounts for 85 to 95% by mass of the foamed ceramic skeleton.

Step 2: Pretreatment of the silicon carbide foam ceramic skeleton: the sintered silicon carbide foam ceramic skeleton is cleaned. The carbon nanotube aqueous solution prepared by using the multi-wall carbon nanotubes purchased from Shenzhen Nanoport Co., Ltd. as a raw material is covered with the spraying process to the surface of the skeleton, and then placed in a box furnace after being naturally dried, and kept at a temperature of 100 to 150 ° C for 30 ～. At 60 min, a dried carbon nanotube layer was obtained. The thickness of the carbon layer is 50-300 μm, and the microstructure of the multi-walled carbon nanotube on the SiC foam ceramic skeleton is shown in Fig. 3C.

Step 3: Design of the brake disc and its casting mold: firstly carry out computer modeling and simulation calculation according to user requirements and drawings provided. According to computer modeling, simulation calculation data and actual production situation, the Al/SiC _foam composite brake disc can be designed and fabricated with 5~10mm thick silicon carbide foam ceramic skeleton composite friction layer, and the non-friction surface of the disc body. A steel casting mold in which a plurality of plate-shaped heat dissipation ribs are integrally molded. The length of the long side of the plate-shaped heat dissipation rib is 20 to 120 mm, and the length of the short side is 3 to 20 mm. A total of 20 reinforcing ribs are evenly distributed on the non-friction surface of the disk body at intervals of 18° in the circumferential direction. The friction layer is integrally cast with a ventilation groove of 3 to 4 mm wide and 5 to 8 mm deep, and the side of the ventilation groove has a draft angle of 4°, and a mounting hole is evenly distributed on the disk body. The arc-shaped surface transition is adopted between the plate-shaped heat dissipation rib and the non-friction surface of the disk body, and the fillet radius is 2 to 40 mm. The mold is designed with a positioning groove for preventing the ceramic skeleton from drifting during the casting process, and the sand core is designed with positioning blocks and rams for preventing the network ceramic skeleton from drifting during the casting process.

Step 4: Low-pressure casting of the brake disc: The silicon carbide foam ceramic skeleton and the sand core are placed in the cavity of the steel mold according to the design requirements. At the mold temperature of 300-500 ° C, the aluminum alloy (ZL111, ie ZAlSi9Cu2Mg, alloy composition weight The percentage Si is 8.0 to 10.0%, Cu is 1.3 to 1.8%, Mg is 0.4 to 0.6%, Mn is 0.10 to 0.35%, Ti is 0.10 to 0.35%, and the balance is Al. When the melt temperature is 700 to 750 ° C, low pressure casting is started. In the liquid lifting stage, the pressing time is 0.5 to 5 s; in the filling stage, the metal liquid surface rising speed is 20 mm/s, the filling speed is 3 kg/s, the filling time is 0.5 to 4 s, and the filling supercharging speed is 0.030 MPa/s; In the pressurization stage, the pressure is increased by 0.035 MPa on the basis of the filling pressure increase value, and the dwell time is 2 to 20 s; in the pressure solidification stage, the time is 150 to 300 s. The silicon carbide foam ceramic skeleton is combined with the aluminum alloy to obtain a brake disc, and the sand core is removed after the mold is cooled. The volume percentage of the silicon carbide foam ceramics in the composite friction layer of the aluminum alloy composite is 10 to 50%, and the percentage of the total volume of the brake disc is 5 to 25%. As one of the processes for optimizing the microstructure of the brake disc, a transition mass element and a rare earth element with a mass percentage of 0.1% to 5% may be added to the molten aluminum alloy to improve the yield strength of the aluminum alloy and the silicon carbide and aluminum alloy. Interface strength. As an optimization process for increasing the elongation and tensile strength of the brake disc, it is also possible to use a one-dimensional, two-dimensional carbon material such as a carbon nanotube having an average particle diameter of 20 to 100 nm and graphene. The low-pressure casting method is used to compound the silicon carbide foam ceramic skeleton with the ZL111 aluminum alloy, thereby avoiding defects such as sedimentation due to density difference between the metal and the ceramic material, performance difference caused by uneven composition, and difficulty in controlling the casting process. The specific strength and heat dissipation are obviously superior to the cast steel and cast iron brake discs, and overcome the defects such as cracks and hot spots which are easily generated when the cast steel and cast iron discs are braked. Compared with cast steel and cast iron brake discs, the weight loss is as high as 40-70%, and the temperature is reduced at high speed and ramp braking, which ensures the safety of the car and the effectiveness of braking.

Step 5: Heat treatment of the brake disc: The brake disc adopts a T6 heat treatment process. After the heat treatment, the tensile strength of the aluminum matrix reaches 300 MPa or more, and the tensile strength at 200 ° C is still greater than 200 MPa.

4 is a photograph showing the macrostructure of a silicon carbide foam ceramic and a ZL111 aluminum alloy composite material after T6 heat treatment. Figure 5 is a photograph of the microstructure of the aluminum alloy material of the disc disk.

Step 6: Precision machining of the brake disc: the friction surface of the brake disc and the surface roughness of the disc ring should reach Ra3.2 Upper, the plane of the brake disc and the connecting seat should be perpendicular to the center of its rotation, and the verticality is less than 0.05mm. The flaw detection is free from cracks, looseness, shrinkage, cold separation, insufficient pouring, etc., and meets the requirements of dynamic balance.

Step 7: Finishing the product into the warehouse: The brake discs are inspected one by one, packaged and stored separately.

The finished product was tested according to the AK MARST standard. The temperature and friction coefficient curves of the friction discs in Figure 6-1, 6-2 are shown in different conditions. The test results show that the three-dimensional The friction pair composed of the network silicon carbide ceramic reinforced ZL111 composite brake disc and the brake shoe produced by Liaoning Jiutong is braked at a speed of 180km/h, the maximum temperature of the friction surface of the brake disc is lower than 300°C, and the temperature gradient is small. The average friction coefficient is about 0.36, the friction surface is not bonded, and there is no hot crack and hot spot generation. The braking is stable, the noise is low, the wear rate is low, and the friction and wear performance are good.

Example 2

The structure of the cast silicon carbide foam ceramic skeleton reinforced 7075 aluminum-based composite subway brake disc of the present embodiment is as shown in FIGS. 7-1, 7-2, 7-3 and 7-4, and the friction disc comprises a metal disc. The body 1 and the metal/continuous structural phase ceramic composite friction layer 3 provided on the side of the metal disk body 1. The friction layer 3 is formed from a continuous structural phase ceramic skeleton integrally cast in a metal. The metal disk body 1 is a metal material which is the same as the metal material in the friction layer 3 and is integrally cast with the friction layer 3, and the friction disk is integrally cast with a reinforcing rib 6 and a ventilation groove 4, the reinforcing rib 6 is a metal material which is the same as the metal material in the friction layer 3 and which is integrally cast with the friction layer 3 . The rib 6 is a linear shape disposed in the radial direction of the friction disk. A rectangular axial vent 5-2 is further disposed on the ventilation groove 4 of the friction disk. A positioning cross pin hole 8 is evenly distributed on the metal disk body 1, and the mounting hole 7 is evenly distributed on the friction disk.

The manufacturing process of the silicon carbide foam ceramic skeleton reinforced 7075 aluminum matrix composite brake disc is as follows:

Step 1: Preparation of three-dimensional grid silicon carbide ceramic skeleton: using the same experimental method as in step 1 of Example 1, the experimental conditions were set to a sintering temperature of 2000 to 2250 ° C, and the temperature was maintained for 0.5 to 3 hours, and pressureless sintering was performed to obtain a silicon carbide foam. The ceramic block has a porosity of 40 to 80%, a mesh diameter of 2 to 6 mm, a density of 2.6 to 3.2 g/cm3, a Vickers hardness (Hv) of 10 to 25 GPa, a flexural strength of 2 to 35 MPa, a compressive strength of 5 to 60 MPa, and heat conduction. The rate is 80 to 100 W/(m·K), wherein the silicon carbide accounts for 96 to 99% by weight.

Step 2: Pretreatment of the network ceramic skeleton: The sintered silicon carbide ceramic skeleton is cleaned. A small amount of carbon black and petroleum coke are added to a conductive carbon paste for screen printing having a solid content of carbon of about 50% by weight, which is purchased from Shenzhen Meitu Silk Screen Printing Co., Ltd., and then ground, and the solid content of carbon in the carbon slurry reaches about After 60wt%, it is covered by the spray process on the surface of the silicon carbide ceramic skeleton. After being dried naturally, it is placed in a box furnace and kept at 100-150 °C for 30-60 minutes to obtain dry carbon with a thickness of 100-500 μm. And graphite layer. As an optimization process, the network ceramic skeleton can be first incubated in an oxidizing atmosphere furnace at 800 ° C for 1 to 5 h, after the surface is formed into a thin layer of silicon oxide, and then immersed in the carbon slurry in step 2 for 30 to 60 minutes. Dry out.

Step 3: Design of brake disc and casting mold: In the same manner as in step 3 of Example 1, a steel casting mold capable of integrally casting a friction layer of a 5 to 15 mm thick silicon carbide foam ceramic skeleton composite material was designed and manufactured. As an optimized design, the friction disc of the brake disc of the present embodiment is uniformly distributed with a ventilation slot of 5 to 12 mm in the circumferential direction at intervals of 60°, and the ventilation slot has a rectangular ventilation hole in the axial direction, and 12 mounting holes are evenly distributed on the disc body. The brake disc is integrally cast with a friction layer of 8mm thick silicon carbide foam ceramic composite. The shape of the rib is one or a combination of a slat, a cylinder, an elliptical cylinder, a T-shape, and an I-shape. In order to prevent the network ceramic skeleton from drifting during the casting process, the positioning groove and the positioning block and the ejector are designed in the mold.

Step 4: Low-pressure casting of the brake disc: The silicon carbide foam ceramic skeleton and the coated sand core are placed in the cavity of the steel mold according to the design requirements. At the mold temperature of 300 ° C, the aluminum alloy (7075, alloy composition weight percentage Si0) .4%, Cu 1.2-2.0%, Mg 2.1-2.9%, Mn 0.35%, Ti 0.1-0.5%, Zn 5.1-6.1%, Cr 0.18-0.28%, balance Al) melt temperature 700-750 Low pressure casting begins at °C. In the liquid lifting stage, the pressurizing time is 2 to 8 s; in the filling stage, the metal liquid surface rising speed is 1 to 9 mm/s, the filling type is 2 to 8 kg/s, the filling time is 3 to 15 s, and the filling supercharging speed is 0.005～0.006MPa/s; in the pressurization stage, the pressure is increased by 0.010MPa based on the filling pressure value, and the holding time is 5-20s; in the pressure solidification stage, the time is 50-300s, the foam ceramic skeleton The brake disc is obtained by integrating with the aluminum alloy. The silicon carbide foam ceramic accounts for 10 to 50% by volume of the aluminum alloy composite. As one of the processes for increasing the elongation and tensile strength of the brake disc, the nano-ceramic particles having an average particle diameter of 20 to 300 nm are used for strengthening and toughening, and the ceramic particles are silicon carbide (SiC), titanium carbide (TiC), carbon nitrogen. One or more of titanium oxide (TiCN), aluminum oxide (Al ₂ O ₃ ), copper oxide (CuO), and silicon oxide (SiO ₂ ). As the second optimization process for improving the microstructure of castings, composite casting technology combined with external fields such as electromagnetic fields and ultrasonic waves is used to refine grains and reduce segregation caused by casting.

Step 5: Heat treatment of the brake disc: The brake disc adopts the T6 heat treatment process. After the heat treatment, the tensile strength of the aluminum base reaches 415 MPa, the tensile strength at 300 ° C is 300 MPa, and the thermal expansion coefficient of the aluminum alloy reinforced with the nano ceramic particles. The elongation is increased by 3% and the elongation is increased by 3%.

Step 6: Precision machining of the brake disc: the friction surface of the brake disc and the surface roughness of the disc ring should reach Ra3.2 or above, and the plane of the brake disc and the connecting seat should be perpendicular to the center of rotation, and the perpendicularity is less than 0.05. Mm, through the flaw detection, no defects such as cracks, looseness, shrinkage, cold separation, and insufficient pouring, and meet the requirements of dynamic balance.

The 640 mm outer diameter silicon carbide foam ceramic reinforced aluminum alloy composite subway brake disc manufactured by the method of the present invention was tested in accordance with the UIC541-3 standard for a 1:1 braking force bench test. The test data shows that the brake disc has a maximum temperature of 406 °C when the brake disc is at a speed of 80 km/h and a large energy of 55 kW for ten minutes, compared to cast iron, cast steel, and forging. The steel brake disc minimizes the temperature rise and temperature gradient of the brake disc. After the test, the friction surface was free from sticking and hot spots, and no visible hot cracks were produced. The average friction coefficient was 0.37. The brake was stable, the noise was low, and there was no wear, showing good friction and wear performance. Compared with cast iron, cast steel, and forged steel brake discs, the weight loss is 40-65%. The test data is shown in Figures 8, 9-1-9-3. Figure 8 is the test data of the friction disc of the subway; 9-1 is the experimental result of the friction coefficient of the subway friction disc under different speeds and pressures, and 9-2 is the experimental result of the temperature rise of the large friction of the subway friction disc. , 9-3 is the test result of the friction coefficient of the large friction of the subway friction disc.

Example 3

The structure of the silicon carbide foam ceramic skeleton reinforced 5083 aluminum-based composite brake disc cast in this embodiment is as shown in FIGS. 10-1 to 10-5, and the friction disc includes a metal disc body 1 and a metal disc body 1 One side of the metal/continuous structural phase ceramic composite friction layer 3. The friction layer 3 is formed from a continuous structural phase ceramic skeleton integrally cast in a metal. The metal disk body 1 is a metal material which is the same as the metal material in the friction layer 3 and is integrally cast with the friction layer 3, and the friction disk is integrally cast with a reinforcing rib 6 and a ventilation groove 4, the reinforcing rib 6 is a metal material which is the same as the metal material in the friction layer 3 and which is integrally cast with the friction layer 3 . The rib 6 is a linear shape disposed in the radial direction of the friction disk. A rectangular axial vent 5-2 is further disposed on the rib 6 of the friction disc. Mounting holes 7 are evenly distributed on the metal disk body 1.

The manufacturing process of the silicon carbide foam ceramic skeleton reinforced 5083 aluminum matrix composite brake disc is as follows:

Step 1: Preparation of a three-dimensional grid silicon carbide ceramic skeleton: a three-dimensional printing forming method is used to prepare a ceramic green body according to a certain proportion of the prepared slurry to be dried and trimmed. Using a pressureless sintering method, the sintering temperature is 1800 to 2200 ° C, and the temperature is maintained for 3 hours, and a silicon carbide foam ceramic block having a length of 300 mm, a width of 300 mm, and a thickness of 7 to 10 mm is obtained, which is laser-cut into a desired reinforcement shape. The porosity of the silicon carbide foam ceramic is about 60 to 70%, the mesh diameter is 2 to 5 mm, the mass percentage of silicon carbide in the silicon carbide ceramic is 97%, the density of the ceramic skeleton is 2.9 g/cm3, and the Vickers hardness (Hv). 20GPa, flexural strength 8～10MPa, compressive strength 45～50MPa, thermal conductivity 120～130W/(m·K).

Step 2: Pretreatment of the ceramic foam skeleton: After the sintered silicon carbide foam ceramic skeleton is cleaned and dried, the surface of the skeleton is plated with Ni, Cu, Ti, Cr, etc. having a thickness of 80 to 400 μm by electroplating. Metal film, then carbon black and petroleum coke are added to the printing ink for a long time grinding. When the carbon content in the carbon slurry reaches about 60% by weight, the surface of the skeleton is covered by a spraying process, and is dried naturally. After being placed in a box furnace and kept at 100-150 ° C for 30-60 min, a dry carbon and graphite layer having a thickness of 100-500 μm is obtained, and the microstructure thereof is shown in FIG. 3B.

Step 3: Design of the brake disc and its casting mold: computer modeling and simulation calculation according to user requirements and drawings provided. According to the computer modeling, simulation calculation data and actual production situation, the steel casting mold with 7~10mm thick silicon carbide foam ceramic skeleton/aluminum alloy composite friction layer is designed and manufactured. The friction surface of the friction disc is provided with 24 trapezoidal ventilation slots, the width of the ventilation slot is 4-10 mm, and the ventilation slot is centered on the rotation axis of the brake disc, extending from the inner circumference of the brake disc to the outer circumference, and the ventilation slot shaft There are rectangular vents in the middle, the size of the vents is (3 ~ 9) × (20 ~ 40) mm ² ; the non-friction surface of the brake disc is evenly spaced by 15° in the circumferential direction. a rib and a second radial reinforcing rib. The venting hole in the axial middle portion of the ventilation groove penetrates the first radial reinforcing rib and the second radial reinforcing rib and is provided with a collecting vent at the bottom end. In addition, the brake disc can also be provided with a venting hole which is not penetrated, and is located at a central portion of the back surface of the friction surface. In order to prevent the network ceramic skeleton from drifting during the casting process, a ram device for pressing the ceramic skeleton is designed in the mold.

Step 4: Low-pressure casting of the brake disc: The silicon carbide foam ceramic skeleton is placed in a steel mold cavity preheated to 350-500 ° C according to design requirements, and the molten metal temperature of the aluminum alloy (5083 aluminum alloy) is 680-720. Low pressure casting begins at °C. In the liquid lifting stage, the pressurizing time is 2 to 12 s; in the filling stage, the metal liquid surface rising speed is 1 to 10 mm/s, the filling speed is 1 to 10 kg/s, the filling time is 2 to 20 s, and the filling supercharging speed is 0.004. MPa/s; pressurization stage, pressurization 0.010~0.050MPa on the basis of filling pressure value, holding time 5~50s; pressure solidification stage, time 100~500s, composite of network ceramic skeleton and aluminum alloy Get the brake disc in one.

As one of the optimization processes, a transition group or a rare earth element having a mass percentage of 0.1 to 5% is added to the aluminum alloy melt to improve the interface strength between the silicon carbide and the aluminum alloy.

As the second optimization process, a transition mass or a rare earth element with a mass percentage of 0.1 to 5% is added to the molten aluminum alloy to increase the interfacial strength between the silicon carbide and the aluminum alloy, and 0.1 to 5% by volume of the nano-ceramic particles are added. Improve the strength of aluminum alloys. The ceramic particles are one or more of silicon carbide (SiC), titanium carbide (TiC), titanium carbonitride (TiCN), aluminum oxide (Al ₂ O ₃ ), copper oxide (CuO), silicon oxide (SiO ₂ ), and the like. Kind.

Step 5: Heat treatment of the brake disc: The brake disc adopts the T61 heat treatment process. After the heat treatment, the tensile strength of the aluminum disc reaches 420 MPa, the yield strength reaches 340 MPa, and the elongation is 4%.

Step 6: Precision machining of the brake disc: the friction surface of the brake disc and the surface roughness Ra of the disc ring are 0.8 to 1.6. The plane of the disc ring, the hub and the connecting seat should be perpendicular to the center of rotation, and the perpendicularity is less than 0.01 mm. After flaw detection, there are no defects such as cracks, looseness, shrinkage, cold separation, and insufficient pouring, and meet the requirements of dynamic balance.

The high-speed iron brake discs we produced are composed of the powder metallurgy brake discs produced by Knorr-Bremse. The test program prepared according to the technical conditions of the iron total TJ/CL310-2013 is tested with a 1:1 brake force bench test. When the brake disc is braked at 50-380km/h, the maximum temperature of the brake disc is 515 °C, no visible hot cracks are produced, and it shows good friction and wear performance. See 11-1, 11-2 for test data. , 12-1, 12-2. Figure 11-1 and 11-2 are the test data of the high-speed friction disk, Figure 11-2 is followed by Figure 11-1; Figure 12-1 is the experimental result of the friction coefficient of the high-speed friction disk at different speeds and pressures, 12 -2 is the experimental result of the friction coefficient of different speeds, pressures and water spray conditions of high-speed friction discs.

Example 4

The structure of the silicon carbide foam ceramic skeleton reinforced steel moving plate cast in this embodiment is as shown in FIGS. 13-1 and 13-2, and the friction disk comprises a metal disk body 1 and a metal symmetrically disposed on both sides of the metal disk body 1. /Continuous structural phase ceramic composite friction layer 3. The friction layer 3 is formed from a continuous structural phase ceramic skeleton integrally cast in a metal. The metal disk body 1 is a metal/continuous structural phase ceramic composite material which is the same material as the friction layer 3 and is integrally cast with the friction layer 3, and the ventilation disk 4 is integrally cast with the ventilation groove 4. An axial vent 5-2 is evenly distributed on the friction disc, and a block 9 is evenly distributed outside the friction disc.

The structure of the silicon carbide foam ceramic skeleton reinforced copper alloy static disk cast in this embodiment is as shown in FIGS. 13-3 and 13-4, and the friction disk comprises a metal disk body 1 and symmetrically disposed on both sides of the metal disk body 1. Metal/continuous structural phase ceramic composite friction layer 3. The friction layer 3 is formed from a continuous structural phase ceramic skeleton integrally cast in a metal. The metal disk body 1 is a metal/continuous structural phase ceramic composite material which is the same material as the friction layer 3 and is integrally cast with the friction layer 3, and the ventilation disk 4 is integrally cast with the ventilation groove 4. An axial venting hole 5-2 is evenly distributed on the friction disc, and a slider 9 is evenly distributed inside the friction disc.

Step 1: Preparation of three-dimensional grid silicon carbide ceramic skeleton: using the same experimental method as in step 1 of Example 1, the experimental conditions were set to a sintering temperature of 1800 to 2200 ° C, and the temperature was kept for 1 to 3 hours, and pressureless sintering was performed to obtain a silicon carbide foam. The ceramic block has a porosity of 60 to 70% and a mesh diameter of 2 to 5 mm, wherein the silicon carbide accounts for 98% by weight.

Step 2: Pretreatment of the ceramic foam skeleton: The sintered silicon carbide foam ceramic skeleton is placed in an oxidizing atmosphere furnace at 800 to 950 ° C for 0.5 to 12 hours to obtain a silicon oxide film of 20 to 500 μm. The microstructure is shown in Figure 3A.

Step 3: Design of brake disc and its casting mold: According to computer modeling, simulation calculation data and actual production situation, design and manufacture steel which can integrally cast 10~15mm thick silicon carbide foam ceramic skeleton/steel composite moving disc A casting mold and a graphite mold capable of integrally casting a 10 to 15 mm thick silicon carbide foam ceramic skeleton/copper alloy composite static disk. In order to prevent the network ceramic skeleton from drifting during the casting process, a positioning groove and a pressing ram device for preventing the movement and drift of the ceramic skeleton are designed in the mold.

Step 4: Vacuum-pressure casting of silicon carbide foam ceramic skeleton reinforced steel moving plate and silicon carbide foam ceramic skeleton reinforced copper alloy static plate:

1 Place the silicon carbide foam ceramic skeleton in the cavity of the steel mold according to the design requirements. When the mold temperature is 350-500 ° C, the vacuum degree of the mold cavity is lower than 1500 Pa, and the molten steel temperature is 1550 ~ 1750 ° C, the molten steel is applied. Vacuum-pressure casting was started at a pressure of 0.05 to 0.25 MPa to obtain a three-dimensional network of silicon carbide ceramic skeleton/steel composite aircraft moving disc.

2 Place the silicon carbide foam ceramic skeleton in the graphite mold cavity according to the design requirements. When the mold temperature is 350-500 ° C, the vacuum degree of the mold cavity is lower than 2000 Pa, and the copper alloy melt temperature is 1150-1250 ° C, the copper alloy is given. The solution is applied with a pressure of 0.05 to 0.25 MPa to start vacuum-pressure casting, and the silicon carbide foam ceramic skeleton is integrated with the copper alloy. Get the plane static.

Step 5: Heat treatment of the brake disc:

1 SiC foam ceramic skeleton reinforced steel moving plate adopts corresponding normalizing or annealing process according to the selected steel grade

2 SiC foam ceramic skeleton reinforced copper alloy static plate according to the selected copper alloy grade using the corresponding annealing process

Step 6: Precision machining of the brake disc: the friction surface of the brake disc and the surface roughness Ra of the disc ring are 0.8 to 1.6. The plane of the disc ring, the hub and the connecting seat should be perpendicular to the center of rotation, and the perpendicularity is less than 0.01 mm. After flaw detection, there are no defects such as cracks, looseness, shrinkage, cold separation, and insufficient pouring, which meet the requirements of dynamic balance.

The silicon carbide foam ceramic skeleton reinforced steel moving plate and the silicon carbide foam ceramic skeleton reinforced copper alloy static disk are combined. The 1:1 braking force bench test is carried out according to the GJB1184-2005A standard. The test results are shown in Figures 14-1 and 14. As shown in Fig. 2, the friction pair can meet the normal and stop take-off braking requirements of the aircraft, the braking distance is short, the maximum temperature of the brake disc is only 900 ° C, and no visible hot cracks are produced, showing good friction and wear performance.

Embodiment 5 clutch plate

The clutch plate structure of the present embodiment is as shown in Figs. 15-1 and 15-2. The clutch plate of the present embodiment comprises a metal disk body 1 and a metal/continuous structural phase ceramic composite friction layer 3 mechanically riveted to both sides thereof; The friction layer 3 is a metal/continuous structural phase ceramic skeleton composite material, and the metal disk body 1 is a steel disk. The clutch plate friction layer 3 is provided with a ventilation groove 4 and a riveting hole. The metal disk body 1 is provided with a riveting hole for riveting the friction layer 3, and the ventilation groove is provided with an axial ventilation hole 5-2, and the metal disk body 1 is provided. Mounting holes 7 and blocks 9 for evenly connecting to the rotating disk hub are provided.

The above production method of the composite clutch plate for a rotary motion machine is as follows:

Step 1: Preparation of planar grid silicon carbide ceramic skeleton: SiC powder with an average particle size of 0.5 μm; boron carbide powder with an average particle size of 2 μm; graphene with an average thickness of 80 nm, an average diameter of 100 μm, and a bulk density of 0.030 g/cm 3 Cubic boron nitride powder having an average particle size of 1 μm, 92 wt.% of SiC powder by weight, 1.5 wt.% of boron carbide powder, 5 wt.% of graphene, 1.5 wt.% of cubic boron nitride, and placed in alumina Ball ball barrel, ball to material ratio of 3:1, then add DOLAPIX PCN dispersant, ZUSOPLAST PS1 plasticizer, binder, carboxymethyl cellulose (CMC), defoamer, etc. 60r/min, the slurry was mixed at a pH of 10 to 12 for 24 hours to obtain a mixed slurry having a uniform solid content of 45 to 55 vol%. The above silicon carbide slurry is poured into a plaster mold to prepare a ceramic green body and dried. The pressureless sintering method is used, the sintering temperature is 1800 to 2200 ° C, and the temperature is kept for 1 to 3 hours, and a silicon carbide ceramic block having a length of 300 mm, a width of 300 mm, and a thickness of 5 to 15 mm is obtained, and is cut into a desired reinforcement shape by a water knife.

Step 2: Pretreatment of the planar grid silicon carbide ceramic skeleton: the sintered planar grid silicon carbide ceramic skeleton is placed in an oxidizing atmosphere furnace at 800-950 ° C for 0.5 to 12 hours to obtain a layer of 20 to 500 μm. Silicon oxide film. Or After cleaning the planar grid ceramic skeleton, chemically or electrochemically coating the surface of the ceramic skeleton with a film of chromium oxide, cerium oxide, titanium oxide, rare earth oxide or alkaline earth oxide having a thickness of 20 to 500 μm; or thickness 20 A film of a metal such as Ni, Cu, Ti, or Cr of -500 μm. In this embodiment, the surface of the ceramic skeleton is preferentially treated by an electrochemical method, and the surface of the ceramic skeleton is covered with a Cu film having a thickness of 250 μm. After being dried, it is placed in a box furnace at 120 ° C for 8 to 12 hours.

Step 3: Design of the clutch plate and its casting mold: According to the design requirements and drawings, select the appropriate metal material, and then carry out the computer modeling of the casting mold and the simulation calculation of the clutch structure according to the casting method of the selected metal material. According to computer modeling, simulation calculation data and actual production situation, design and manufacture a steel casting mold capable of integrally casting a 15mm thick planar grid silicon carbide ceramic skeleton/aluminum alloy composite friction layer, and can integrally cast a 15mm thick plane. Graphite casting mold for grid silicon carbide ceramic skeleton/copper alloy composite friction layer. In order to prevent the planar grid silicon carbide ceramic skeleton from drifting during the casting process, a ram device for pressing the planar grid silicon carbide ceramic skeleton is designed in the mold.

Step 4: Pressure Casting of Planar Grid Silicon Carbide Ceramic Skeleton Reinforced Aluminum Alloy Composite Friction Layer and Vacuum-Pressure Casting of Friction Layer of Planar Grid Silicon Carbide Ceramic Skeleton Reinforced Copper Alloy Composite

1 Place the planar grid silicon carbide ceramic skeleton in the cavity of the steel mold according to the design requirements. When the aluminum alloy melt temperature is 680-750 °C, apply pressure of 0.5-50 MPa to the aluminum alloy solution to start pressure casting. SiC ceramic skeleton / aluminum alloy composite friction layer.

2 Place the planar grid silicon carbide ceramic skeleton in the graphite mold cavity according to the design requirements. When the mold temperature is 350-500 °C, the vacuum degree of the mold cavity is lower than 2000Pa, and the copper alloy melt temperature is 1150～1250°C, give The copper alloy solution is subjected to vacuum-pressure casting by applying a pressure of 0.05 to 0.25 MPa, and the planar mesh silicon carbide ceramic skeleton is combined with the copper alloy to obtain a composite friction layer.

Step 5: Heat treatment of the clutch plates:

The planar grid silicon carbide ceramic skeleton/aluminum alloy composite friction layer adopts the corresponding solid solution strengthening heat treatment process according to the grade of the selected aluminum alloy.

The planar mesh silicon carbide ceramic skeleton/copper alloy composite friction layer adopts the corresponding annealing process according to the grade of the selected copper alloy.

Step 6: Precision machining of the clutch plate: riveting the planar mesh silicon carbide ceramic skeleton/aluminum alloy composite friction layer and the planar mesh silicon carbide ceramic skeleton/copper alloy composite friction layer and the metal back plate respectively, and then according to The surface roughness Ra of the friction surface and the disc ring is 0.8-1.6. The plane of the disc ring, the hub and the connecting seat should be perpendicular to the center of rotation, and the perpendicularity is less than 0.01 mm for machining. No flaws, looseness, shrinkage, and detection are detected through the flaw detection. Defects such as cold separation and insufficient pouring meet the requirements of dynamic balance.

The ceramic skeleton of the present invention can be selected from a variety of structures, preparation methods, and pretreatment methods to suit the design and use requirements of different friction discs. Only a few of them are listed below, but are not exhaustive of the embodiments thereof.

Example 6 Preparation and Pretreatment of Periodically Laminated Ceramic Framework

Fig. 16 shows several different forms of the periodic laminated structure. The laminated unit of the periodic laminated ceramic skeleton is an octahedron, a hexahedron, a tetrahedron, a quadrangular pyramid or a fullerene structure, and the skeleton cross section is circular, elliptical or semicircular. Or a polygon.

Preparation of a ceramic skeleton of a periodic laminated structure: silicon carbide, silicon nitride powder and graphite having a purity of >98% and an average particle diameter of d50=1.0 μm are first prepared to form a silicon carbide-bonded silicon nitride multiphase ceramic. In this embodiment, a hexagonal silicon carbide-bonded silicon nitride multiphase ceramic skeleton is taken as an example, and the skeleton is a laminated structure, each layer is connected by a hexagon, and the cross section of the skeleton is a square of 2 mm×2 mm, and the length of the skeleton is 3mm. A plaster mold for grouting is prepared according to the designed skeleton structure. The slurry is defoamed in a vacuum and then injected into a mold and cured at 60 to 80 ° C for 12 to 24 hours. After solidification, the mold is released, and a blank body having a smooth, dense, uniform, high-strength periodic laminated structure is obtained. The green body is dried at 80-200 ° C for 24 to 48 h, and then sintered at 1900 to 2100 ° C for 0.5 to 1.5 h under an argon atmosphere of 8 to 10 atm to obtain a silicon carbide length of 300 mm, a width of 300 mm, and a height of 5 to 15 mm. A 70% by weight, regular-formed, periodic laminated structure of silicon carbide-bonded silicon nitride multiphase ceramic blocks was cut into the desired reinforcement shape with a water knife.

Pretreatment of the periodic laminated ceramic skeleton: After the periodic laminated structure of silicon carbide is bonded with the silicon nitride ceramic skeleton, the skeleton is pretreated by electroplating.

Example 7 Preparation and Pretreatment of Ceramic Grid of Planar Grid Structure

Figure 17 is a schematic view showing the structure of a planar grid structure having a grid shape square. In addition, the mesh shape of the planar structure may also be circular, elliptical, semi-circular or polygonal, and the number of meshes per square centimeter is 1-15.

Preparation of alumina-silicon carbide grid structure ceramic skeleton: In this embodiment, a ceramic skeleton is prepared by dry pressing. The raw materials were alumina powder and silicon carbide powder having a purity of >99% and an average particle diameter of d50 = 0.5 μm. The mass percentage of the alumina powder is 15 to 30%, and the mass percentage of the silicon carbide powder is 70 to 85%. The PVA aqueous solution is uniformly mixed by ball milling and then granulated. A steel mold for dry press forming was prepared according to the side length of the alumina-silicon carbide composite ceramic skeleton of 4 mm, the distance between adjacent grids of 2 mm, and the hexagonal grid length of 10 mm. The granulated alumina-silicon carbide ceramic powder was dry-formed in a steel mold under a pressure of 150 MPa to obtain a green body. The green body was sintered in an argon atmosphere at a pressure of 0.15 MPa and 1850 ° C for 0.5 h to obtain a ceramic skeleton having an accurate size, a uniform microstructure, and a regular appearance.

Pretreatment of alumina-silicon carbide grid structure ceramic skeleton: After cleaning the ceramic skeleton, the ceramic skeleton is surface treated by electrochemical method, and the surface of the ceramic skeleton is covered with a metal Ni film with a thickness of 100-250 μm. After drying, it is placed in a 120 ° C box furnace for 8 to 12 hours.

Example 8 Preparation and Pretreatment of Continuous Columnar Ceramic Framework

Figure 18 is a schematic view showing the structure of a continuous columnar structure in which a continuous array of columnar unit structures is formed, the columnar unit having a hexagonal cross section. Further, the columnar unit of the continuous columnar structure may also be circular, elliptical, semi-circular or polygonal.

Preparation of columnar array silicon carbide ceramic skeleton: a silicon carbide slurry prepared according to a certain ratio is injected into a silica gel mold, and a cylindrical columnar array of ceramic green body is prepared by gel injection molding and dried, and then the reaction is utilized. The sintering method, the sintering temperature is 1300 to 1800 ° C, and the temperature is kept for 1 to 3 hours, and a silicon carbide cylindrical columnar array structure ceramic block having a length of 300 mm, a width of 300 mm, and a thickness of 5 to 15 mm is obtained, and cut into a desired shape with a water knife. In the columnar array structure, silicon carbide accounts for 80 to 90% by weight of the mass of silicon carbide.

Pretreatment of columnar array silicon carbide ceramic skeleton: After cleaning and drying the sintered columnar array structure silicon carbide ceramic, the surface of the skeleton is plated with Ni or Cu or Ti or Cr with a thickness of 80-400 μm by electroplating. The metal film is then covered with a layer of carbon or graphite by spraying. It is naturally dried and placed in a box furnace at 100-150 ° C for 30-60 min to obtain a dry carbon or graphite layer with a thickness of 300-500 μm. .

Example 9 Pretreatment method of ceramic skeleton

The pretreatment as in the spray method described in Example 1 can be selected, and the microstructure of the treated ceramic skeleton is as shown in Fig. 3C. The pretreatment as in the electroplating method described in Example 3 can also be selected, and the microstructure of the treated ceramic skeleton is as shown in Fig. 3B. The pretreatment of the oxidizing atmosphere coating as described in Example 4 can also be selected, and the microstructure of the treated ceramic skeleton is as shown in Fig. 3A. It is also possible not to perform pretreatment, and its surface is as shown in Fig. 3D. Ceramic skeletons with different optimization properties can be obtained through different pretreatment methods.

Example 10 Preparation of a mold for the metal/continuous structural phase ceramic composite

According to the user's requirements and the drawings provided, the appropriate metal materials are selected first, and then the computer simulation calculation of the brake disc structure and the modeling of the casting mold are carried out according to the selected metal material casting method. Design and manufacture steel casting molds based on computer simulation calculation data, modeling and actual production. The lower mold is as shown in FIG. 19-1, and is provided with a positioning groove 11 for placing a ceramic skeleton, and a positioning block 10 is disposed between the adjacent positioning grooves 11, and is in the upper mold (as shown in FIG. 19-2). The positioning groove 11 of the display is provided with a plurality of ejector pins 12 at corresponding positions. The arrangement of the positioning groove 11, the positioning block 10 and the ram 12 prevents the ceramic skeleton from drifting during the casting process. The shape of the casting mold positioning groove 11 is the same as that of the continuous structure phase ceramic skeleton 2; the positioning block 10 and the ejector 12 may have a circular, elliptical, rectangular or hexagonal cross section.

However, when it is necessary to integrally cast the symmetrical friction layer 3 and the friction disk having the vent holes between the friction layers 3, it is necessary to use the sand core 13, which is a coated sand core for casting. A schematic view of the structure of the sand core 13 is shown in Figs. 20-1 and 20-2. The sand A positioning block 10 is disposed on the core 13 at a position corresponding to the groove 14 on the ceramic frame, and a plurality of ejector pins 12 are disposed at corresponding positions of the continuous structural phase ceramic frame 2. The function of the positioning block 10 and the ejector pin is to prevent the ceramic skeleton from moving and drifting. The cross section of the positioning block 10 and the jack 12 may be circular, elliptical, rectangular or hexagonal.

Claims

A metal/continuous structural phase ceramic composite friction disk characterized by:

The friction disc comprises a metal disc body (1) and a metal/continuous structural phase ceramic composite friction layer (3) disposed on one side of the metal disc body (1) or symmetrically disposed on both sides thereof;

The metal disk body (1) is a metal back plate mechanically connected to the friction layer (3); or is formed of a composite material which is the same as the friction material layer (3) and is integrally cast with the friction layer (3); Or it is formed of a metal material which is the same as the metal material in the friction layer (3) and is integrally cast with the friction layer (3); or is made of the same material as the metal material in the friction layer (3), and the friction layer (3) A metal material integrally formed and having a reinforcing rib (6).
The metal/continuous structural phase ceramic composite friction disk according to claim 1, wherein:

The mechanical connection of the metal backing plate to the friction layer (3) means: riveting, welding or bolting.
The metal/continuous structural phase ceramic composite friction disk according to claim 2, wherein:

The reinforcing ribs (6) are arranged along the radial direction of the non-friction surface of the friction disc and integrally molded with the friction layer (3), and the reinforcing ribs have a straight line or a curved shape.
The metal/continuous structural phase ceramic composite friction disk according to claim 3, wherein:

The shape of the reinforcing rib (6) is one of a lath, a cylinder, an elliptical cylinder, a T-shape, and an I-shape, or a combination of several.
The metal/continuous structural phase ceramic composite friction disk according to claim 3, wherein:

The friction disc is provided with a venting hole, and the venting hole comprises a radial venting hole (5-1) disposed along a radial direction of the disk body and/or an axial venting hole (5-2) disposed along the axial direction of the disk body. ;

The axial venting hole (5-2) is formed by a hole penetrating through or not through the friction disk body, and the outline thereof is circular, elliptical, rectangular or hexagonal;

When the friction disc has a symmetrical friction layer (3), the radial venting holes (5-1) are formed by a straight line in the circumferential direction of the non-friction surface of the friction disc or a hole between the curved reinforcing ribs (6);

Alternatively, when the friction disc has a friction layer (3), the radial vent (5-1) is between the straight line or the curved rib (6) in the circumferential direction of the non-friction surface of the two friction discs Hole formation;

Alternatively, when the friction disc has a friction layer (3), the radial vent (5-1) is a straight or curved rib (6) and other metal discs in the circumferential direction of the non-friction surface of the friction disc. (1) The formed hole is formed.
A metal/continuous structural phase ceramic composite friction disk according to claim 5, wherein:

The friction layer (3) is integrally cast with a ventilation groove (4) in a radial direction; the ventilation groove (4) is linear or curved in the radial direction.
The metal/continuous structural phase ceramic composite friction disk according to claim 6, wherein:

The friction disc is integrally molded with a mounting hole (7) or a block (9) for connecting with a rotating disk or a rotating shaft of the moving member; the outline of the mounting hole (7) or the block (9) is a circle Shape, oval, rectangular or hexagonal.
The metal/continuous structural phase ceramic composite friction disk according to claim 7, wherein:

The continuous structural phase ceramic is a continuous structural phase ceramic skeleton (2);

The continuous structural phase ceramic skeleton (2) in the friction layer (3) accounts for 5 to 60% by volume of the friction layer (3); and has a thickness of 2 to 35 mm.
The metal/continuous structural phase ceramic composite friction disk according to claim 8, wherein:

The continuous structural phase ceramic skeleton (2) is divided into: a silicon carbide ceramic skeleton, a silicon nitride ceramic skeleton, an alumina ceramic skeleton, a zirconia ceramic skeleton, a mullite ceramic skeleton, or a silicon carbide or nitrogen according to different materials. a composite ceramic skeleton of silicon, alumina, and zirconia;

The silicon carbide, silicon nitride, aluminum oxide, zirconium oxide, mullite in the continuous structural phase ceramic skeleton (2); or the total quality of the ceramic skeleton of silicon carbide, silicon nitride, aluminum oxide and zirconia composite ceramics The percentage is 60 to 99% by weight.
A metal/continuous structural phase ceramic composite friction disk according to claim 8 wherein:

The structure of the continuous structural phase ceramic skeleton (2) is a periodic laminated structure, a planar lattice structure, a continuous columnar structure or a three-dimensional network continuous structure;

Wherein the periodic laminated structure ceramic skeleton is a stack of octahedrons, hexahedrons, tetrahedrons, quadrangular pyramids, fullerenes or other structures, and the skeleton cross section is a circle, an ellipse, a rectangle, a hexagon or other geometric shapes;

The holes in the ceramic frame of the planar grid structure are circles, ellipses, rectangles, hexagons, triangles or other geometric shapes, and the number of grids per square centimeter is 1 to 15;

The cross section of the pillar in the continuous columnar ceramic skeleton is circular, elliptical, rhombic, rectangular, hexagonal, triangular or other geometric shape;

The three-dimensional network continuous structure ceramic skeleton is interconnected in a three-dimensional direction, the porosity is 40 to 90%, and the mesh diameter is 0.5 to 8 mm.
The metal/continuous structural phase ceramic composite friction disk according to claim 10, wherein:

The material of the metal material in the metal disk body (1) of the friction disk and the metal/continuous structure phase ceramic composite material is: aluminum alloy, magnesium alloy, titanium alloy, high temperature alloy, copper alloy, iron or steel.
The metal/continuous structural phase ceramic composite friction disk according to claim 11, wherein the aluminum alloy is a ZLXXX, 7XXX, 6XXX, 5XXX, 4XXX, 2XXX or 1XXX series aluminum alloy.
The metal/continuous structural phase ceramic composite friction disk according to claim 12, wherein:

The aluminum alloy, magnesium alloy, titanium alloy, high temperature alloy, copper alloy, iron or steel is strengthened and toughened by a one-dimensional or two-dimensional carbon material having an average particle diameter of 20 to 100 nm and a volume percentage of 0.1 to 5% of the metal. The one-dimensional or two-dimensional carbon material is carbon nanotube or graphene;

Alternatively, the aluminum alloy, the magnesium alloy, the titanium alloy, the high temperature alloy, the copper alloy, the iron or the steel is reinforced and toughened by using nano ceramic particles having an average particle diameter of 20 to 500 nm and a volume percentage of the metal of 0.1 to 5%. The nano ceramic particles are silicon carbide, titanium carbide, titanium carbonitride, aluminum oxide, copper oxide or silicon oxide.
A method of fabricating a metal/continuous structural phase ceramic composite friction disk according to any of claims 1-13, characterized in that:

The casting method used in the production of the friction disc is atmospheric pressure casting, low pressure casting, pressure casting, negative pressure casting, differential pressure casting or vacuum-pressure casting; or the above casting method is combined with electromagnetic field or combined with ultrasonic wave casting;

During production, the molten metal is cast into a cavity in which the continuous structural phase ceramic skeleton (2) is fixed, thereby obtaining a friction disk integrally molded with a metal/continuous structural phase ceramic composite friction layer (3); The friction metal layer of the cast metal/continuous structural phase ceramic composite material (3) is mechanically combined with the metal back plate to obtain a friction disc; and then the precision processing or heat treatment + precision machining is performed to obtain the finished friction disc.
The method for manufacturing a metal/continuous structural phase ceramic composite friction disk according to claim 14, wherein the ceramic skeleton in the friction disk is prepared by a template grouting method, a precursor impregnation method, and a gel injection. Molding method, foaming method, addition pore-forming agent method, sol-gel method, freeze-drying method, dry pressing forming method, isostatic pressing method or three-dimensional printing method;

In the production, the ceramic skeleton body is first prepared, and then a ceramic skeleton having a length of 10 to 300 mm, a width of 10 to 300 mm, and a thickness of 2 to 35 mm is obtained by reaction sintering, pressureless sintering or hot pressing sintering; silicon carbide, nitrogen Silicon, alumina, zirconia, mullite, or silicon carbide, silicon nitride, alumina, zirconia multiphase ceramics account for 60 to 99% by weight of the total mass of the ceramic skeleton, and the rest are sintering aids or sintering The phase is added, and the sintering aid or the sintering addition phase is selected from the group consisting of boron carbide, carbon, silicon oxide, aluminum oxide, cerium oxide, silicon nitride, titanium diboride, zirconium diboride or molybdenum disilide.
The method for manufacturing a metal/continuous structural phase ceramic composite friction disk according to claim 15, wherein the surface of the continuous structural phase ceramic skeleton (2) is pretreated, if the pretreatment method is as follows:

The continuous structural phase ceramic skeleton (2) is placed in an oxidizing atmosphere furnace at 800 to 950 ° C for 0.5 to 12 hours to obtain a layer of an oxide film of 20 to 500 μm;

Or spraying a layer of carbon or graphite with carbon nanotubes, petroleum coke, carbon black, conductive carbon paste, printing ink or graphite on the surface of the continuous structural phase ceramic skeleton (2), and drying a carbon or graphite layer having a thickness of 20 to 500 μm;

Or chemically or electrochemically treat the continuous structural phase ceramic skeleton (2) with a surface layer covered with a thickness of 20-500 μm of chromium oxide, cerium oxide, titanium oxide, rare earth oxides, alkaline earth oxides. Or a film of metallic Ni, Cu, Ti, Cr.
A casting mold for use in a method for producing a metal/continuous structural phase ceramic composite friction disk according to claim 14, wherein:

The casting mold has a disc shape, and includes an upper mold, a lower mold and a gate provided on the mold; the lower mold cavity is provided with a positioning groove (11) and a positioning block for preventing movement and drift of the ceramic skeleton. (10); the upper mold is provided with a ram (12) for preventing movement and drift of the ceramic skeleton;

For integrally forming a friction disc having a vent hole between the symmetric friction layers (3), the casting mold further includes a sand core (13), and the upper half of the sand core (13) is provided to prevent the ceramic skeleton from moving, a drifting positioning block (10); the lower half of the sand core is provided with a ram (12) for preventing movement and drift of the ceramic skeleton;

The shape of the positioning groove (11) of the casting mold is the same as the shape of the continuous structure phase ceramic skeleton (2); the positioning block (10) and the ram (12) may have a circular or elliptical cross section. , rectangular or hexagonal.