WO2019090445A1 - 耐磨材料、局部增强轻金属基复合材料及制备方法 - Google Patents

耐磨材料、局部增强轻金属基复合材料及制备方法 Download PDF

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WO2019090445A1
WO2019090445A1 PCT/CN2017/000702 CN2017000702W WO2019090445A1 WO 2019090445 A1 WO2019090445 A1 WO 2019090445A1 CN 2017000702 W CN2017000702 W CN 2017000702W WO 2019090445 A1 WO2019090445 A1 WO 2019090445A1
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particles
fiber
wear
metal
light metal
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PCT/CN2017/000702
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English (en)
French (fr)
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齐霖
齐丕骧
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宁波海瑞时新材料有限公司
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Priority to US16/071,078 priority Critical patent/US20210171403A1/en
Publication of WO2019090445A1 publication Critical patent/WO2019090445A1/zh

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    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52Constituents or additives characterised by their shapes
    • C04B2235/5208Fibers
    • C04B2235/526Fibers characterised by the length of the fibers
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    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52Constituents or additives characterised by their shapes
    • C04B2235/5208Fibers
    • C04B2235/5264Fibers characterised by the diameter of the fibers
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602Making the green bodies or pre-forms by moulding
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    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/616Liquid infiltration of green bodies or pre-forms
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    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/08Alloys with open or closed pores
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    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C47/00Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/14Making alloys containing metallic or non-metallic fibres or filaments by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C49/00Alloys containing metallic or non-metallic fibres or filaments
    • C22C49/02Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
    • C22C49/10Refractory metals
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    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C49/00Alloys containing metallic or non-metallic fibres or filaments
    • C22C49/14Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00Technologies relating to the processing of minerals
    • Y02P40/60Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

Definitions

  • the invention relates to the technical field of wear-resistant materials and local reinforced metal matrix composite materials, in particular to a wear-resistant material, a light metal-based composite material partially reinforced by the wear-resistant material and a preparation method of the light metal matrix composite material.
  • Wear-resistant materials are an important basic material in industrial production and are closely related to modern production and life.
  • the most common wear-resistant mechanisms in everyday life are automotive brake hubs and brake discs.
  • the brake hub and brake disc are the key safety parts on the car, which play the role of friction braking and require good wear resistance and comprehensive mechanical properties.
  • automobile brake hubs and brake discs at home and abroad are mostly cast in cast iron.
  • the cast iron brake hub and brake disc have the following disadvantages: 1.
  • the cast iron density is high and the density is about 7.3g/cm 2 , so the brake hub and the brake disc are heavier, and the brake hub and brake disc are heavy.
  • the weight belongs to the non-sprung weight, which is equivalent to 3 to 5 times the sprung weight, which will undoubtedly increase the fuel consumption of the vehicle and reduce the maneuverability of the vehicle. In addition, the disassembly and repair of related components is difficult; 2.
  • the thermal conductivity of cast iron is poor. The heat generated by the friction during braking is slow, which may cause the brake system to malfunction due to excessive temperature rise. 3.
  • Cast iron brake hubs and brake discs are generally cast with sand. The dimensional accuracy and surface finish of the castings are poor. The internal shrinkage porosity is not easy to control, and the labor intensity of casting production is high, which is harmful to the environment.
  • a first technical problem to be solved by the present invention is to provide a wear resistant material.
  • a second technical problem to be solved by the present invention is to provide a light metal matrix composite material which is locally reinforced by the wear resistant material.
  • a third technical problem to be solved by the present invention is to provide a method for preparing a light metal matrix composite.
  • an abrasion resistant material the composition of the wear resistant material comprising a high temperature resistant metal skeleton material having a mass ratio of (10 to 60): (1 to 30): (10 to 70).
  • the ceramic fiber material and the ceramic particulate material, the high temperature resistant metal skeleton material is a foam metal or a high temperature resistant metal fiber, and the high temperature resistant metal fiber comprises an iron-based alloy fiber, a nickel-based alloy fiber, a copper-based alloy fiber, and a stainless steel.
  • the ceramic particle material comprises fly ash particles, slag powder particles, silicon carbide particles, silica particles, boron nitride particles, zircon powder particles, brown One or more of corundum particles, zirconium oxide particles, zirconium silicate particles, and chromium oxide particles.
  • the ceramic particulate material is mixed with auxiliary reinforcing particles, the auxiliary reinforcing particles are graphite particles and/or steel slag particles, and the steel slag particles are iron oxide particles, zinc oxide particles, calcium oxide particles, and oxidation.
  • auxiliary reinforcing particles are graphite particles and/or steel slag particles
  • steel slag particles are iron oxide particles, zinc oxide particles, calcium oxide particles, and oxidation.
  • magnesium particles, alumina particles, and titanium oxide particles are one or more of magnesium particles, alumina particles, and titanium oxide particles.
  • the metal foam is copper foam, iron foam, nickel foam or iron iron foam.
  • the ceramic fiber material has a diameter of 5 to 15 ⁇ m and a length of 0.8 to 2.8 mm
  • the high temperature resistant metal fiber has a diameter of 0.01 to 2 mm
  • the ceramic particulate material has a particle size of 5 to 200 ⁇ m.
  • the Mohs hardness is 5 to 9, and the foam metal has a porosity of 10 to 60 ppm.
  • the composition of the wear-resistant layer comprises a mass ratio of (10-60): (1-30): (10 ⁇ ) 70): (0.5-8): (0.5-10) high temperature resistant metal skeleton material, ceramic fiber material, ceramic particulate material, low temperature binder and high temperature binder;
  • the high temperature resistant metal skeleton material is foam metal Or a high temperature resistant metal fiber, the refractory metal fiber comprising one of an iron-based alloy fiber, a nickel-based alloy fiber, a copper-based alloy fiber, a stainless steel fiber, a steel wool fiber, a titanium-based alloy fiber, and a cobalt-based alloy fiber or
  • the ceramic fiber material comprises one or more of alumina fiber, aluminum silicate fiber, silica fiber, zirconia fiber, silicon carbide fiber, graphite fiber and
  • the ceramic particulate material is mixed with auxiliary reinforcing particles, the auxiliary reinforcing particles are graphite particles and/or steel slag particles, and the steel slag particles are iron oxide particles, zinc oxide particles, calcium oxide particles, and oxidation.
  • auxiliary reinforcing particles are graphite particles and/or steel slag particles
  • steel slag particles are iron oxide particles, zinc oxide particles, calcium oxide particles, and oxidation.
  • magnesium particles, alumina particles, and titanium oxide particles are one or more of magnesium particles, alumina particles, and titanium oxide particles.
  • the metal foam is copper foam, iron foam, nickel foam or iron iron foam.
  • the ceramic fiber material has a diameter of 5 to 15 ⁇ m and a length of 0.8 to 2.8 mm
  • the high temperature resistant metal fiber has a diameter of 0.01 to 2 mm
  • the ceramic particulate material has a particle size of 5 to 200 ⁇ m.
  • the Mohs hardness is 5 to 9, and the foam metal has a porosity of 10 to 60 ppm.
  • the preparation method of the above partially-reinforced light metal matrix composite material comprises the following steps: 1 to 30% of ceramic fiber material, 10 to 70% of ceramic particle material, 0.5 to 8% of low temperature binder and 0.5 by mass fraction. ⁇ 10% high temperature binder, add appropriate amount of water to mix uniformly to make ceramic slurry, then the pottery
  • the porcelain slurry is quantitatively poured into a pre-formed mold pre-filled with a high-temperature resistant metal skeleton, pressurized at 20-30 MPa, dewatered and pressed into a semi-finished product of the composite preform; then the composite preform is first at a temperature of 60-200 ° C
  • the drying process is carried out for 10 to 20 hours, and then sintered at a temperature of 700 to 1000 ° C for 2.5 to 4 hours to obtain a finished composite preform.
  • the composite preform is compounded into a previously prepared light metal alloy by an extrusion casting process.
  • the base body metallurgically combines the wear layer preform with the light
  • the high temperature resistant metal skeleton is formed by: processing a metal foam by means of machining, and processing a sheet material matching the shape and size of the wear layer to obtain a high temperature resistant metal skeleton, or
  • the high temperature resistant metal fiber is combed, processed, woven, and tiled into a mold of the skeleton preform and compacted to obtain a high temperature resistant metal skeleton.
  • the composition of the wear resistant material disclosed in the present invention comprises a high temperature resistant metal skeleton material, a ceramic fiber material and a ceramic particulate material having a mass ratio of (10 to 60): (1 to 30): (10 to 20), and abrasion resistance.
  • Good, strong toughness suitable for occasions with high requirements on wear resistance and toughness, can be partially compounded on the surface of light metal alloy substrate to improve the wear resistance and toughness of light metal alloy matrix at high temperature;
  • the locally reinforced light metal matrix composite material disclosed by the invention has selective local strengthening of the light metal alloy substrate by the wear resistant material of the invention, and forms a wear layer on the surface of the light metal alloy substrate to improve its resistance at high temperature. Grindability and toughness; in addition, the light metal alloy base is light in weight, and it is made into a brake hub or brake disc of an automobile or a train, and the wear layer of the present invention is combined on the working surface thereof, compared with the existing cast iron. Brake hub or brake disc, the surface wear resistance can be increased to more than 4 times that of the existing cast iron brake hub or brake disc, and the weight is reduced by more than half, and the thermal conductivity of light metal alloy such as aluminum and magnesium is better than that of cast iron.
  • the operating temperature of the brake hub (or brake disc) can be reduced by nearly 100 ° C; at the same time, due to the reduction of the vehicle
  • the weight, especially the sprung weight can reduce the fuel consumption of the vehicle, reduce the raw material cost, processing cost and maintenance cost of the brake system such as automobiles and trains, improve the vehicle passing performance, shorten the braking distance, and improve the safety of the vehicle;
  • the partially reinforced light metal matrix composite material disclosed by the invention can replace the existing aluminum matrix composite material reinforced only by ceramics, and is formed into a high horsepower diesel engine insert ring piston by using an extrusion casting process, while maintaining the original insert ring piston Under the premise of service life, the use temperature of the piston can be increased by 50-100 °C, thereby improving the output of the diesel engine, saving fuel consumption and reducing exhaust emissions;
  • the partially reinforced light metal matrix composite material disclosed by the invention can replace the homogeneous aluminum alloy material of the existing steel sleeve, and is directly formed into a composite material with the wear resistant material of the invention by an extrusion casting process.
  • the magnesium alloy load wheel of the tracked vehicle can reduce the weight of the 1/3 load wheel and reduce the vibration and noise of the vehicle while maintaining the wear resistance and service life of the original load wheel.
  • the preparation method of the locally reinforced light metal matrix composite material disclosed by the invention has strong operability.
  • the preparation method metallurgically combines the wear-resistant layer with the light metal alloy substrate by an extrusion casting process, and the light metal alloy liquid penetrates into the porous preform to form a composite material in the extrusion casting process, and the wear-resistant layer and the light metal alloy matrix metallurgy of the composite material are formed.
  • the combination ensures that the wear resistance and comprehensive mechanical properties of the locally reinforced light metal matrix composite meet the requirements for use.
  • FIG. 1 is a schematic structural view of an aluminum alloy automobile brake disc having a wear layer prepared in Embodiment 1;
  • Example 2 is a schematic view showing the structure of a magnesium alloy truck brake hub having a wear layer prepared in Example 2.
  • Example 1 Preparation of an aluminum alloy automobile brake disc having a wear-resistant layer made of a cast aluminum alloy of the American grade A356, having a size of ⁇ 288 mm (outer diameter) ⁇ 44.6 mm (thickness), which is resistant
  • the grinding layer is a ring having a size of ⁇ 288 mm (outer diameter) ⁇ 184 mm (inner diameter) ⁇ 3 mm (thickness).
  • the preparation method comprises the following steps:
  • a foamed copper having a thickness of 10 to 60 ppm and a thickness of 10 mm is machined into ⁇ 288 mm (outer diameter) ⁇ 184 mm (inner diameter) ⁇ 10 mm (thickness) to obtain a high-temperature resistant metal skeleton, and a high temperature resistant metal skeleton is placed. Preformed in the mold;
  • the aluminum alloy automobile brake disc integral blank was heat-treated and mechanically processed by T6 to obtain the finished aluminum alloy automobile brake disc with the wear layer of the first embodiment, and its structural schematic view is shown in Fig. 1.
  • the aluminum alloy automobile brake disc shown in FIG. 1 comprises an aluminum alloy brake disc body 1 , and the two working surfaces of the aluminum alloy brake disc body 1 are respectively combined with a wear layer 2 and two wear layers 2
  • the six support members 3 are connected to each other along the circumferential direction of the two wear layers 2 via the six support ribs 3.
  • Example 2 Preparation of a magnesium alloy truck brake hub having a wear resistant layer, the automotive brake hub is made of American grade Made of cast magnesium alloy of AZ91D, the size is ⁇ 480mm (outer diameter) ⁇ 227mm (height), and the size of the wear-resistant layer is ⁇ 420mm (outer diameter) ⁇ 180mm (height) ⁇ 7mm (wall thickness).
  • the preparation method comprises the following steps:
  • the ceramic slurry is immersed in the gap of the steel fiber under the action of centrifugal force, and a part of the water is removed to obtain a cylindrical preform blank having a size of ⁇ 420 mm (inner diameter) ⁇ 180 mm (height) ⁇ 12 mm (wall thickness) ;
  • the size of the finished product is ⁇ 420mm (outer diameter) ⁇ 180mm (height) ⁇ 12mm (thickness); then the preform blank is first dried at 100 ° C temperature After treatment for 15h, and then sintering at 800 ° C for 3h, to obtain a finished product;
  • the magnesium alloy truck brake hub blank was heat treated and machined by T6 to obtain the finished product of the magnesium alloy truck brake hub with wear layer of Example 2.
  • the structure is shown in Fig. 2.
  • the magnesium alloy truck brake hub shown in FIG. 2 includes a cylindrical magnesium alloy brake hub body 1 and an inner wall of the magnesium alloy brake hub body 1 in which a cylindrical wear layer 2 is combined.

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Abstract

一种耐磨材料、局部增强轻金属基复合材料及制备方法,该耐磨材料的组成包括质量比为(10~60)∶(1~30)∶(10~70)的耐高温金属骨架材料、陶瓷纤维材料和陶瓷颗粒材料,耐高温金属骨架材料为泡沫金属或耐高温金属纤维,该耐磨材料耐磨性好、强韧性高,适用于对耐磨性、强韧性要求较高的场合,可局部复合于轻金属合金基体的表面,提高轻金属合金基体高温下的耐磨性和强韧性;局部增强轻金属基复合材料,通过耐磨材料进行局部强化的轻金属合金基体,可制成重量轻、耐磨性好、导热性好的制动毂或制动盘,提高车辆安全性;局部增强轻金属基复合材料的制备方法,通过挤压铸造工艺将耐磨层与轻金属合金基体冶金结合,确保复合材料的耐磨性和综合力学性能满足使用要求。

Description

耐磨材料、局部增强轻金属基复合材料及制备方法 技术领域
本发明涉及耐磨材料及局部增强金属基复合材料技术领域,具体是一种耐磨材料、利用该耐磨材料进行局部增强的轻金属基复合材料及该轻金属基复合材料的制备方法。
背景技术
耐磨材料是工业生产中的一种重要的基础材料,与现代化生产和生活密切相关。日常生活中最常见的耐磨机构是汽车制动毂和制动盘。制动毂和制动盘为汽车上关键的安全件,起摩擦制动作用,要求具有良好的耐磨性及综合力学性能。在行车过程中,制动毂或制动盘能否安全可靠地制动非常重要,若紧急情况下发生刹车失灵,将会造成安全事故,甚至造成车毁人亡大事故。因此,制动毂和制动盘是非常重要的安全件。历来,国内外的汽车制动毂和制动盘大多是用铸铁整体铸造而成,其耐磨性和力学性能好,铸造工艺成熟,可成形复杂通风孔,价格较低,适合大批量生产。但是铸铁制动毂和制动盘有下列不足处;1、铸铁密度高,密度达7.3g/cm2左右,因此制动毂和制动盘的重量较重,而制动毂和制动盘的重量属于非簧载重量,相当于3~5倍的簧载重量,无疑会明显增加车辆油耗,降低车辆机动性能,此外,相关部件拆装、维修较困难;2、铸铁的导热性较差,刹车时磨擦产生的热量散发慢,易造成刹车系统因温升过高而工作失灵。3、铸铁制动毂和制动盘一般用型砂铸造,铸件尺寸精度、表面光洁度差,内部缩松气孔不易控制,且铸造生产的劳动强度高,对环境污染较大。
发明内容
本发明所要解决的第一个技术问题是提供一种耐磨材料。
本发明所要解决的第二个技术问题是提供一种利用该耐磨材料进行局部增强的轻金属基复合材料。
本发明所要解决的第三个技术问题是提供一种轻金属基复合材料的制备方法。
本发明解决上述技术问题所采用的技术方案为:耐磨材料,该耐磨材料的组成包括质量比为(10~60)∶(1~30)∶(10~70)的耐高温金属骨架材料、陶瓷纤维材料和陶瓷颗粒材料,所述的耐高温金属骨架材料为泡沫金属或耐高温金属纤维,所述的耐高温金属纤维包括铁基合金纤维、镍基合金纤维、铜基合金纤维、不锈钢纤维、钢棉纤维、钛基合金纤维和钴基合金纤维中的一种或多种,所述的陶瓷纤维材料包括氧化铝纤维、硅酸铝纤维、二氧化硅纤维、氧化锆纤维、碳化硅纤维、石墨纤维和碳纤维中的一种或多种,所述的陶瓷颗粒材料包括粉煤灰颗粒、矿渣微粉颗粒、碳化硅颗粒、二氧化硅颗粒、氮化硼颗粒、锆英粉颗粒、棕刚玉颗粒、氧化锆颗粒、硅酸锆颗粒和氧化铬颗粒中的一种或多种。
作为优选,所述的陶瓷颗粒材料中混合有辅助增强颗粒,所述的辅助增强颗粒为石墨颗粒和/或钢渣颗粒,所述的钢渣颗粒为氧化铁颗粒、氧化锌颗粒、氧化钙颗粒、氧化镁颗粒、氧化铝颗粒和氧化钛颗粒中的一种或多种。
作为优选,所述的泡沫金属为泡沫铜、泡沫铁、泡沫镍或泡沫铁镍。
作为优选,所述的陶瓷纤维材料的直径为5~15μm、长度为0.8~2.8mm,所述的耐高温金属纤维的直径为0.01~2mm,所述的陶瓷颗粒材料的粒度为5~200μm、莫氏硬度为5~9,所述的泡沫金属的孔隙度为10~60ppm。
局部增强轻金属基复合材料,包括轻金属合金基体及局部复合于该轻金属 合金基体表面的耐磨层,所述的轻金属合金基体为铝合金基体或镁合金基体,所述的耐磨层的组成包括质量比为(10~60)∶(1~30)∶(10~70)∶(0.5~8)∶(0.5~10)的耐高温金属骨架材料、陶瓷纤维材料、陶瓷颗粒材料、低温粘合剂和高温粘合剂;所述的耐高温金属骨架材料为泡沫金属或耐高温金属纤维,所述的耐高温金属纤维包括铁基合金纤维、镍基合金纤维、铜基合金纤维、不锈钢纤维、钢棉纤维、钛基合金纤维和钴基合金纤维中的一种或多种,所述的陶瓷纤维材料包括氧化铝纤维、硅酸铝纤维、二氧化硅纤维、氧化锆纤维、碳化硅纤维、石墨纤维和碳纤维中的一种或多种,所述的陶瓷颗粒材料包括粉煤灰颗粒、矿渣微粉颗粒、碳化硅颗粒、二氧化硅颗粒、氮化硼颗粒、锆英粉颗粒、棕刚玉颗粒、氧化锆颗粒、硅酸锆颗粒和氧化铬颗粒中的一种或多种,所述的低温粘合剂是浓度为3~20%的羧甲基纤维素水溶液,所述的高温粘合剂是浓度为10~60%的硅溶胶溶液。
作为优选,所述的陶瓷颗粒材料中混合有辅助增强颗粒,所述的辅助增强颗粒为石墨颗粒和/或钢渣颗粒,所述的钢渣颗粒为氧化铁颗粒、氧化锌颗粒、氧化钙颗粒、氧化镁颗粒、氧化铝颗粒和氧化钛颗粒中的一种或多种。
作为优选,所述的泡沫金属为泡沫铜、泡沫铁、泡沫镍或泡沫铁镍。
作为优选,所述的陶瓷纤维材料的直径为5~15μm、长度为0.8~2.8mm,所述的耐高温金属纤维的直径为0.01~2mm,所述的陶瓷颗粒材料的粒度为5~200μm、莫氏硬度为5~9,所述的泡沫金属的孔隙度为10~60ppm。
上述局部增强轻金属基复合材料的制备方法,包括以下步骤:按质量分数计,将1~30%的陶瓷纤维材料、10~70%的陶瓷颗粒材料、0.5~8%的低温粘合剂和0.5~10%的高温粘合剂,加入适量水均匀混合制成陶瓷浆料,再将该陶 瓷浆料定量浇入预装有耐高温金属骨架的预制件模具中,加压20~30MPa,去水并压制成复合材料预制件半成品;然后将该复合材料预制件先在60~200℃温度下烘干处理10~20h,再在700~1000℃温度下烧结处理2.5~4h,得到复合材料预制件成品;最后采用挤压铸造工艺将该复合材料预制件成品复合于事先准备好的轻金属合金基体,使耐磨层预制件与轻金属合金基体冶金结合,即得到局部增强轻金属基复合材料。
作为优选,所述的耐高温金属骨架的制作过程为:将泡沫金属用机械加工的手段,加工出与所述的耐磨层的形状大小相匹配的板料,得到耐高温金属骨架,或者,将耐高温金属纤维经梳理、加工、编织、平铺至骨架预制件模具中并压实,得到耐高温金属骨架。
与现有技术相比,本发明的优点在于:
1、本发明公开的耐磨材料的组成包括质量比为(10~60)∶(1~30)∶(10~20)的耐高温金属骨架材料、陶瓷纤维材料和陶瓷颗粒材料,耐磨性好、强韧性高,适用于对耐磨性、强韧性要求较高的场合,可局部复合于轻金属合金基体的表面,提高轻金属合金基体高温下的耐磨性和强韧性;
2、本发明公开的局部增强轻金属基复合材料,通过本发明耐磨材料对轻金属合金基体进行有选择性的局部强化,在轻金属合金基体的表面形成耐磨层,以提高其在高温下的耐磨性和强韧性;此外,轻金属合金基体比重轻,将其制成汽车或火车等的制动毂或制动盘并在其工作面上复合本发明耐磨层后,相比于现有铸铁制动毂或制动盘,表面耐磨性可提高到现有铸铁制动毂或制动盘的4倍以上,并减轻一半以上重量,并且,铝镁等轻金属合金的导热性比铸铁好得多,可使制动毂(或制动盘)的工作温度降低近100℃;同时,由于减轻了车辆 重量,尤其是簧上重量,因而可降低车辆油耗,还可减少汽车、火车等制动系统的原材料成本、加工成本及维护成本,改善车辆通过性能,缩短刹车距离,提高车辆安全性等;
3、本发明公开的局部增强轻金属基复合材料,可替代现有仅通过陶瓷增强的铝基复合材料,将其用挤压铸造工艺,做成大马力柴油机镶圈活塞,在保持原镶圈活塞的使用寿命前提下,可提高活塞的使用温度达50~100℃,从而可提高柴油机的输出功率,节约油耗,减少废气排放;
4、本发明公开的局部增强轻金属基复合材料,可取代现有镶钢套的均质铝合金材料,通过挤压铸造工艺,直接成形为带有本发明耐磨材料制成的复合材料耐磨环的履带车辆的镁合金负重轮,在保持原负重轮的耐磨性及使用寿命的前提下,可以减轻1/3负重轮的重量,并减少车辆震动和噪音;
5、本发明公开的局部增强轻金属基复合材料的制备方法,可操作性强。该制备方法通过挤压铸造工艺将耐磨层与轻金属合金基体冶金结合,在挤压铸造过程中轻金属合金液渗入多孔的预制件内形成复合材料,构成复合材料的耐磨层与轻金属合金基体冶金结合,确保局部增强轻金属基复合材料的耐磨性和综合力学性能满足使用要求。
附图说明
图1为实施例1制得的具有耐磨层的铝合金汽车制动盘的结构示意图;
图2为实施例2制得的具有耐磨层的镁合金卡车制动毂的结构示意图。
具体实施方式
以下结合附图实施例对本发明作进一步详细描述。
实施例1:制备具有耐磨层的铝合金汽车制动盘,该汽车制动盘由美国牌号A356的铸造铝合金制成,其尺寸为Φ288mm(外径)×44.6mm(厚度),其耐 磨层为尺寸为Φ288mm(外径)×184mm(内径)×3mm(厚度)的圆环。制备方法包括以下步骤:
(1)将孔隙度为10~60ppm的厚度为10mm的泡沫铜,机械加工成Φ288mm(外径)×184mm(内径)×10mm(厚度),得到耐高温金属骨架,将耐高温金属骨架置于预制件模具中;
(2)按质量分数计,将10%的氧化铝纤维、5%的硅酸铝纤维和40%的粉煤灰颗粒、8%的碳化硅颗粒与3%的羧甲基纤维素水溶液(浓度为20%)和12%的硅熔胶溶液(浓度为50%)与适量水经均匀混合制成陶瓷浆料,再将该陶瓷浆料定量浇入预装有耐高温金属骨架的预制件模具中,先抽真空至1×10-2Pa,再加压20~30MPa,去水并压制成Φ288mm(外径)×184mm(内径)×10mm(厚度)的圆环,再在130℃温度下烘干处理10h、在850℃温度下烧结处理3h,得到预制件单体;
(3)取两个预制件单体,并将这两个预制件单体用六个泡沫铜制成的支撑筋连接,再放入挤压铸造模具的指定位置中,浇入液态的A356铝合金,合模加压,使液态铝合金在压力下渗入多孔的预制件中,并充填满挤压铸造模腔,制得铝合金汽车制动盘整体毛坯,其上下表面帶有耐磨层;
(4)将铝合金汽车制动盘整体毛坯经T6热处理和机械加工,得到实施例1的具有耐磨层的铝合金汽车制动盘成品,其结构示意图见图1。如图1所示的铝合金汽车制动盘,包括铝合金制动盘本体1,铝合金制动盘本体1的两个工作面上分别复合有一层耐磨层2,两层耐磨层2经六个支撑筋3上下相连,六个支撑单元3沿两层耐磨层2的周向间隔设置。
实施例2:制备具有耐磨层的镁合金卡车制动毂,该汽车制动毂由美国牌号 AZ91D的铸造镁合金制成,其尺寸为Φ480mm(外径)×227mm(高度),其耐磨层的尺寸为Φ420mm(外径)×180mm(高度)×7mm(筒壁厚度)。制备方法包括以下步骤:
(1)按质量分数计,将40%的直径为0.4~1mm的高强度钢纤维经梳理、编织,平铺于圆筒形的预制件模具内并压实,制成耐高温金属骨架并置于预制件模具的靠近内壁的部位,再将12%的硅酸铝纤维、41%的碳化硅颗粒与5%的羧甲基纤维素水溶液(浓度为20%)和10%的硅熔胶溶液(浓度为60%)与适量水经均匀混合制成陶瓷浆料,再将该陶瓷浆料定量浇入上述预装有耐高温金属骨架的预制件模具中,使预制件模具绕其中心轴旋转,使陶瓷浆料在离心力作用下浸入钢纤维的缝隙中,并甩掉部分水分,得到圆筒状的预制件毛坯,其尺寸为Φ420mm(内径)×180mm(高度)×12mm(筒壁厚度);
(2)以制成圆筒状的预制件毛坯,该预制件成品的尺寸为Φ420mm(外径)×180mm(高度)×12mm(厚度);然后将预制件毛坯先在100℃温度下烘干处理15h,再在800℃温度下烧结处理3h,得到预制件成品;
(3)将预制件成品放入挤压铸造模具的指定位置中,浇入液态的AZ91D镁合金,合模加压,使液态镁合金在压力下渗入多孔的预制件中,并充填满挤压铸造模腔,制得镁合金卡车制动毂毛坯,其内壁帶有耐磨层;
(4)将镁合金卡车制动毂毛坯经T6热处理和机械加工,得到实施例2的具有耐磨层的镁合金卡车制动毂成品,其结构示意图见图2。如图2所示的镁合金卡车制动毂,包括圆筒状的镁合金制动毂本体1、镁合金制动毂本体1的内壁复合有圆筒状的耐磨层2。

Claims (10)

  1. 耐磨材料,其特征在于:该耐磨材料的组成包括质量比为(10~60)∶(1~30)∶(10~70)的耐高温金属骨架材料、陶瓷纤维材料和陶瓷颗粒材料,所述的耐高温金属骨架材料为泡沫金属或耐高温金属纤维,所述的耐高温金属纤维包括铁基合金纤维、镍基合金纤维、铜基合金纤维、不锈钢纤维、钢棉纤维、钛基合金纤维和钴基合金纤维中的一种或多种,所述的陶瓷纤维材料包括氧化铝纤维、硅酸铝纤维、二氧化硅纤维、氧化锆纤维、碳化硅纤维、石墨纤维和碳纤维中的一种或多种,所述的陶瓷颗粒材料包括粉煤灰颗粒、矿渣微粉颗粒、碳化硅颗粒、二氧化硅颗粒、氮化硼颗粒、锆英粉颗粒、棕刚玉颗粒、氧化锆颗粒、硅酸锆颗粒和氧化铬颗粒中的一种或多种。
  2. 根据权利要求1所述的耐磨材料,其特征在于:所述的陶瓷颗粒材料中混合有辅助增强颗粒,所述的辅助增强颗粒为石墨颗粒和/或钢渣颗粒,所述的钢渣颗粒为氧化铁颗粒、氧化锌颗粒、氧化钙颗粒、氧化镁颗粒、氧化铝颗粒和氧化钛颗粒中的一种或多种。
  3. 根据权利要求1所述的耐磨材料,其特征在于:所述的泡沫金属为泡沫铜、泡沫铁、泡沫镍或泡沫铁镍。
  4. 根据权利要求1所述的耐磨材料,其特征在于:所述的陶瓷纤维材料的直径为5~15μm、长度为0.8~2.8mm,所述的耐高温金属纤维的直径为0.01~2mm,所述的陶瓷颗粒材料的粒度为5~200μm、莫氏硬度为5~9,所述的泡沫金属的孔隙度为10~60ppm。
  5. 局部增强轻金属基复合材料,其特征在于:包括轻金属合金基体及局部复合于该轻金属合金基体表面的耐磨层,所述的轻金属合金基体为铝合金基体 或镁合金基体,所述的耐磨层的组成包括质量比为(10~60)∶(1~30)∶(10~70)∶(0.5~8)∶(0.5~10)的耐高温金属骨架材料、陶瓷纤维材料、陶瓷颗粒材料、低温粘合剂和高温粘合剂;所述的耐高温金属骨架材料为泡沫金属或耐高温金属纤维,所述的耐高温金属纤维包括铁基合金纤维、镍基合金纤维、铜基合金纤维、不锈钢纤维、钢棉纤维、钛基合金纤维和钴基合金纤维中的一种或多种,所述的陶瓷纤维材料包括氧化铝纤维、硅酸铝纤维、二氧化硅纤维、氧化锆纤维、碳化硅纤维、石墨纤维和碳纤维中的一种或多种,所述的陶瓷颗粒材料包括粉煤灰颗粒、矿渣微粉颗粒、碳化硅颗粒、二氧化硅颗粒、氮化硼颗粒、锆英粉颗粒、棕刚玉颗粒、氧化锆颗粒、硅酸锆颗粒和氧化铬颗粒中的一种或多种,所述的低温粘合剂是浓度为3~20%的羧甲基纤维素水溶液,所述的高温粘合剂是浓度为10~60%的硅溶胶溶液。
  6. 根据权利要求5所述的局部增强轻金属基复合材料,其特征在于:所述的陶瓷颗粒材料中混合有辅助增强颗粒,所述的辅助增强颗粒为石墨颗粒和/或钢渣颗粒,所述的钢渣颗粒为氧化铁颗粒、氧化锌颗粒、氧化钙颗粒、氧化镁颗粒、氧化铝颗粒和氧化钛颗粒中的一种或多种。
  7. 根据权利要求5所述的局部增强轻金属基复合材料,其特征在于:所述的泡沫金属为泡沫铜、泡沫铁、泡沫镍或泡沫铁镍。
  8. 根据权利要求5所述的局部增强轻金属基复合材料,其特征在于:所述的陶瓷纤维材料的直径为5~15μm、长度为0.8~2.8mm,所述的耐高温金属纤维的直径为0.01~2mm,所述的陶瓷颗粒材料的粒度为5~200μm、莫氏硬度为5~9,所述的泡沫金属的孔隙度为10~60ppm。
  9. 权利要求5~8中任一项所述的局部增强轻金属基复合材料的制备方法, 其特征在于包括以下步骤:按质量分数计,将1~30%的陶瓷纤维材料、10~70%的陶瓷颗粒材料、0.5~8%的低温粘合剂和0.5~10%的高温粘合剂,加入适量水均匀混合制成陶瓷浆料,再将该陶瓷浆料定量浇入预装有耐高温金属骨架的预制件模具中,加压20~30MPa,去水并压制成复合材料预制件半成品;然后将该复合材料预制件先在60~200℃温度下烘干处理10~20h,再在700~1000℃温度下烧结处理2.5~4h,得到复合材料预制件成品;最后采用挤压铸造工艺将该复合材料预制件成品复合于事先准备好的轻金属合金基体,使耐磨层预制件与轻金属合金基体冶金结合,即得到局部增强轻金属基复合材料。
  10. 根据权利要求9所述的局部增强轻金属基复合材料的制备方法,其特征在于:所述的耐高温金属骨架的制作过程为:将泡沫金属用机械加工的手段,加工出与所述的耐磨层的形状大小相匹配的板料,得到耐高温金属骨架,或者,将耐高温金属纤维经梳理、加工、编织、平铺至骨架预制件模具中并压实,得到耐高温金属骨架。
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