CN109210109B

CN109210109B - Power vehicle brake disc and preparation method thereof

Info

Publication number: CN109210109B
Application number: CN201710755876.0A
Authority: CN
Inventors: 秦文隆
Original assignee: Individual
Current assignee: Individual
Priority date: 2017-06-30
Filing date: 2017-08-29
Publication date: 2021-09-24
Anticipated expiration: 2037-08-29
Also published as: CN109210109A; CN207661026U

Abstract

The invention relates to a power vehicle brake disc and a preparation method thereof, wherein the method mainly comprises the steps of preparing a three-dimensional net material, preparing ceramic slurry, preparing a binder, preparing a three-dimensional ceramic framework, preparing a light alloy and preparing a light composite brake disc; the light-weight composite brake disc manufactured according to the method mainly comprises the following components: the brake disc is composed of a body integrally formed by light alloy such as aluminum, aluminum magnesium or titanium and the like and two annular three-dimensional ceramic frameworks with porous gaps, wherein the center of the body is provided with an axis, two surfaces of the body are provided with friction surfaces surrounding the axis, the two friction surfaces are respectively provided with the three-dimensional ceramic frameworks formed with the body, and the pores of the three-dimensional ceramic frameworks are filled with the light alloy, so that the brake disc has the effects of continuous composite strength, high efficiency and high quality for manufacturing the light composite brake disc.

Description

Power vehicle brake disc and preparation method thereof

Technical Field

The invention relates to a power vehicle brake disc and a preparation method thereof, belongs to the technical field of vehicle friction brake elements, and particularly relates to a light-weight composite power vehicle brake disc with continuous composite strength, high efficiency and high quality and a preparation method thereof.

Background

Nowadays, fuel oil and environmental protection regulations around the world are becoming stricter, and in order to improve fuel efficiency and reduce carbon dioxide emission, automobiles must be continuously light-weighted. The light weight of the automobile is always a hot topic, and the concept of the light weight of the automobile is to reduce the overall mass of the automobile as much as possible on the premise of ensuring the strength, rigidity, mode and safety function of the automobile, then improve the dynamic property and controllability of the automobile, reduce fuel consumption and reduce exhaust pollution. To address the need for lightweight vehicles, future applications of automotive materials are expected to fall into three directions: high strength steel, lightweight materials (aluminum/magnesium/ultra high strength steel, etc.), and carbon fiber materials. At present, almost all automobile bodies are steel plates, lightweight materials on one automobile only account for about three, and in the process of material change, high-strength steel and aluminum alloy are developed rapidly at the present stage, and other materials such as ceramic, plastic, glass Fiber or Carbon Fiber Composite (CFRP) materials and the like are also available. According to the research of McKinsey, the lightweight material used on a trolley can reach seven-fold by 2030, and the specific gravity speed increase is most obvious when advanced high-strength steel plates, aluminum alloys and resin materials are used. Taking aluminum alloy as an example, the aluminum alloy is the most used material in the process of automobile light weight, the market scale of aluminum materials worldwide is increasing year by year, and the annual composite growth rate is estimated to be as high as 17.7% from 211 billion dollars in 2012 to 564 billion dollars in 2019. This high growth is due primarily to the light weight, recyclability and formability of aluminum alloy materials. According to the actual measurement, the weight of an aluminum frame can be reduced by 30-40% compared with a steel frame, wherein the weight of an aluminum engine can be reduced by 30%, the weight of an aluminum radiator can be reduced by 20-40% compared with that of a copper frame, and the weight of an automobile aluminum hub can also be reduced by 30%, so that the aluminum alloy material seems to be an ideal material for automobile light weight at the present stage. In the case of fuel-powered vehicles, the most direct benefit of light weight is to reduce fuel consumption, emissions, and air pollution. Compared with the traditional fuel oil automobile, the electric vehicle has more requirements on light weight, the vehicle is light, multiple batteries can be mounted, and the cruising journey is longer.

In addition to the reduction of weight, in a conventional brake disc for a vehicle, it is necessary to increase the frictional force between the brake disc and a brake disc in order to increase the braking efficiency, but when the vehicle is subjected to continuous downhill or emergency braking, the brake disc slips or seizes due to the increase in temperature of the brake disc due to the high temperature generated by the continuous friction, so that the cooling capacity of the brake disc itself must be enhanced, and a composite brake disc made of a light alloy and a ceramic matrix is produced. For example, taiwan patent No. M404157 "porous medium heat dissipation brake disc ventilation disc" (patent publication data reference of 21/05/2011) includes a brake disc ventilation disc having two friction plates and a space spaced between the two friction plates, the spaced space is radially provided with a plurality of flow guiding parts connecting the two friction plates, a plurality of ventilation ducts are formed between the plurality of flow guiding parts, the plurality of ventilation ducts are provided with porous medium heat dissipation metal, so as to effectively increase the contact area of heat dissipation air, the spindle of the wheel is hollow, the forced air flows through the spindle and the grooves on the peripheral surface of the spindle, and the plurality of ventilation ducts radially discharge the air to the brake disc ventilation disc through the porous medium heat dissipation metal to the outside, so as to achieve forced air supply. Chinese patent CN102581259A "ceramic column array-shaped array reinforced metal composite material and its preparation method", its column-shaped ceramic is a single column, and only after one column is fixed in the casting cavity, it can be poured and compounded with metal to form the composite material. Chinese patent CN103104638A "a brake disc made of metal/ceramic composite material for high-speed train", which comprises a metal matrix, and ceramic blocks arranged in the metal matrix, wherein the metal matrix has ventilation slots, and is characterized in that: the ceramic block is obtained by sintering a ceramic green body formed by a ceramic column array and a ceramic substrate which are arranged according to a certain rule, wherein the ceramic column array and the ceramic substrate are made of the same material and are single-phase or complex-phase ceramics of SiC, Al2O3, B4C, Si3N4, Ti3SiC2 and TiB 2. Chinese patent CN103939509A 'A composite material friction pair of Al/SiC and Cu/SiC for railway vehicles and a preparation method thereof', which comprises an Al/Sic brake disc and a Cu/Sic brake pad, wherein the brake pad is connected to a braking clamp of a railway vehicle through a back plate, the brake disc is fixedly arranged on a hub or a wheel of the railway vehicle through a mounting hole, and the friction surface of the brake pad is abutted against the friction surface of the brake disc; the brake pad is characterized in that a network silicon carbide ceramic framework is embedded on a friction surface of the brake pad, a plurality of radiating fins and a base body form the back surface of the brake pad, ventilation grooves penetrating through the brake disc are formed in the middle of radiating ribs, the silicon carbide ceramic framework accounts for 10-50 vol% of a silicon carbide ceramic/aluminum alloy composite material, the silicon carbide ceramic framework accounts for 5-40 vol% of the whole brake disc, the silicon carbide ceramic framework accounts for 10-50 vol% of the silicon carbide ceramic/copper alloy composite material, the silicon carbide ceramic framework accounts for 5-40 vol% of the whole brake pad, the network silicon carbide ceramic sheet embedded in the brake disc is 5-15 mm thick, and the network silicon carbide ceramic sheet embedded in the brake pad is 5-18 mm thick.

As described above, the ceramic-reinforced metal matrix composite material, particularly the silicon carbide ceramic-reinforced aluminum matrix, copper matrix and other metal composite materials with porous structures, is used for friction elements of high-speed vehicles, and can significantly reduce unsprung weight and achieve light weight. The silicon carbide ceramic has excellent performances of high modulus, high wear resistance, high strength, low density and the like, while the metal material has good toughness, and the silicon carbide is made into a porous ceramic framework and then compounded with metal, so that the prepared metal ceramic composite material not only can exert the advantages of high hardness, high wear resistance and high heat resistance of the silicon carbide ceramic, but also can fully exert the advantages of high toughness, good heat conductivity and the like of the metal material, and is an ideal friction material. The friction surface of the brake disc is made of Al/Sic composite material, and the silicon carbide ceramic forms hard micro-protrusions to play a bearing role in the braking process, so that the plastic deformation and high-temperature softening of aluminum alloy are inhibited, and the high-temperature friction performance of the composite material can be obviously improved. Even if the aluminum is softened or even melted by the high temperature generated by friction heat, the aluminum matrix is difficult to generate serious adhesive abrasion under the action of shearing force because the aluminum in the pores is limited by the framework, thereby avoiding bonding. In the prior art, ceramic reinforcements are in many shapes, including particles, fibers, whiskers, porous or three-dimensional webs, and the like. The particle, fiber and whisker reinforced phase is the most common reinforced body, but the reinforced phase and metal are compounded to form a discontinuous interface, and the reinforced phase is easy to fall off in the braking process, so that the performance of the composite material is greatly reduced. The three-dimensional mesh ceramic reinforced metal matrix composite material is greatly limited because the closed pore problem of the mesh ceramic cannot be effectively solved and the mesh ceramic reinforced metal matrix composite material is difficult to cast into a defect-free product.

Disclosure of Invention

The main purpose of the present invention is to solve the above problems and to provide a light weight composite power vehicle brake disc with continuous composite strength, high efficiency and high quality and a method for manufacturing the same, the method of the present invention mainly comprises three-dimensional net material preparation, ceramic slurry preparation, binder preparation, three-dimensional ceramic skeleton preparation, light alloy preparation and light weight composite brake disc preparation:

preparing a three-dimensional net material, namely foaming polyurethane polymers into foam with three-dimensional pores, then cutting the foam into preset shapes, sizes and thicknesses, and performing surface treatment for later use if necessary;

preparing a binder, namely stirring and heating phosphoric acid or phosphate, aluminum hydroxide and water which are prepared in proportion to react to form sol for later use;

preparing ceramic slurry, namely uniformly mixing alumina, aluminum hydroxide, silicate kaolin and silicon carbide or corundum alumina which are prepared according to a certain proportion into powdery raw materials, adding water according to a certain proportion into the prepared binder, uniformly stirring, adding the powdery raw materials, and stirring into viscous ceramic slurry for later use;

preparing a three-dimensional ceramic skeleton, pouring ceramic slurry into three-dimensional ceramic skeleton automatic molding equipment, placing a three-dimensional net material on a conveying device, performing a slurry injecting, impregnating, extruding and absorbing program, extruding and removing a residual slurry program on the three-dimensional net material, turning the three-dimensional net material by one hundred eighty degrees, performing a slurry injecting, impregnating, extruding and absorbing program again, removing a residual slurry program on the three-dimensional net material, performing blowing and absorbing program to ensure that the ceramic slurry is uniformly distributed, after confirming that three-dimensional pores are smooth, transferring into a continuous reaction curing program, curing the three-dimensional net material into a ceramic skeleton blank with certain strength, performing a sintering program, heating, sintering and strengthening, and cooling to obtain the three-dimensional ceramic skeleton for later use;

preparing light alloy, namely heating and melting light alloy such as aluminum, aluminum magnesium or titanium and the like into light alloy soup for hot-pressing feeding;

preparing the light-weight composite brake disc, namely fixing the three-dimensional ceramic skeleton into a metal mould of the brake disc, pushing the metal mould into a heating zone of a vacuum atmosphere pressure impregnation composite forming machine to preheat the metal mould, when the metal mould is preheated, enabling the light alloy soup to flow downwards into the metal mould until a fixed amount is reached, carrying out gas pressure maintaining and vibration shaking impregnation procedures on the metal mould, then carrying out a cooling procedure until the light alloy cooling time is reached, pushing out the vacuum atmosphere pressure impregnation composite forming machine, demoulding, taking out a light-weight composite brake disc blank, and finally carrying out turning and milling to prepare the light-weight composite brake disc.

The invention discloses a light-weight composite brake disc manufactured according to the method, which mainly comprises the following components: the ceramic body is composed of a body integrally formed by light alloy such as aluminum, aluminum magnesium or titanium and the like and two annular three-dimensional ceramic frameworks with multiple pores; the center of the body is provided with an axis, two sides of the body are provided with friction surfaces surrounding the axis, the two friction surfaces are respectively provided with a three-dimensional ceramic framework which is formed together with the body, and the pores of the three-dimensional ceramic framework are filled with light alloy.

The invention also includes a support frame preparation process, the support frame preparation makes rigid materials such as steel plates or carbon fiber plates into a support frame according to the shape of the three-dimensional ceramic skeleton, the contact surfaces of the upper end surface and the lower end surface of the support frame and the three-dimensional ceramic skeleton are provided with holes and limiting parts, the end surface of the support frame near the center is provided with an assembly hole, when the light-weight composite brake disc is prepared, the support frame is placed between two three-dimensional ceramic skeletons and then is fixed in a brake disc metal mold to prepare the light-weight composite brake disc, so that the light-weight alloy, the support frame in the center and the three-dimensional ceramic skeletons at the upper end and the lower end are combined into the light-weight composite brake disc.

The invention discloses a light-weight composite brake disc manufactured according to the method, which mainly comprises the following components: the ceramic frame is composed of a body which is integrally formed by light alloy such as aluminum, aluminum magnesium or titanium, two annular three-dimensional ceramic frameworks with multiple pores, and a supporting frame which is arranged between the two annular three-dimensional ceramic frameworks with multiple pores; the body center has the axle center, and the body both sides have the friction surface of surrounding this axle center, respectively are equipped with the three-dimensional pottery skeleton of shaping together with the body on two friction surfaces, and have the support frame between two three-dimensional pottery skeletons, and this support frame up end, lower terminal surface have hole and spacing portion with three-dimensional pottery skeleton contact surface, have the pilot hole on the nearly central terminal surface of support frame, in this support frame hole, the space that two three-dimensional pottery skeletons are separated by means of spacing portion and the hole of three-dimensional pottery skeleton is filled with light alloy.

The invention has the effects of continuous composite strength, high efficiency and high quality for manufacturing the light-weight composite brake disc.

Drawings

FIG. 1 is a flow chart of the preparation method of the present invention;

FIG. 2 is a cross-sectional view of a lightweight composite brake disk according to an embodiment of the present invention;

FIG. 3 is a plan view of an automatic molding apparatus for a three-dimensional ceramic skeleton according to an embodiment of the present invention;

FIG. 4 is a plan view of a vacuum-atmosphere pressurized impregnation composite molding apparatus according to an embodiment of the present invention;

FIG. 5 is an exploded isometric view of another embodiment of a lightweight composite brake rotor according to the present invention;

FIG. 6 is a cross-sectional view of another embodiment of a lightweight composite brake rotor according to the present invention.

In the figure:

1, a conveying device, 2' an extrusion grouting device; 21. 21' grouting machine; 22. 22' an extrusion device; 3. 3 ', 3' turnover device; 4, an extruding device; 5, a blowing and sucking device; 6, a vacuum atmosphere pressurization impregnation composite forming machine; 60 an inlet airtight door; a heating zone 61; 62 vacuum degassing the operating system; 63 an inlet displacement system; a 64 gas pressurization zone; 65 nitrogen pressurization and vibration shaking impregnation system; 66 forced cooling system; 67 an outlet pusher system; 68 an outlet outer airtight door; 7 light alloy melting equipment; 8, a body; 80 axle center; 81 friction surface; 9, a three-dimensional ceramic skeleton; 90 a support frame; 91 holes; 92 a limiting part; 93 assembly holes; a, three-dimensional net material; and B, a metal mold.

Detailed Description

The present invention is further described with reference to the following drawings and specific examples so that those skilled in the art can better understand the present invention and can practice the present invention, but the examples are not intended to limit the present invention.

The invention aims at a brake disc of a power vehicle, in particular to a light-weight composite brake disc and a preparation method thereof. Referring to fig. 1 and fig. 2, the method of the present invention mainly includes:

preparing a three-dimensional net material, namely foaming polyurethane polymers into foam with three-dimensional pores, then cutting the foam into preset shapes, sizes and thicknesses (the invention is cutting into a ring shape), and performing surface treatment for later use if necessary;

preparing a binder, namely stirring and heating phosphoric acid or phosphate, aluminum hydroxide and water which are prepared in proportion to react to form sol for later use; for example: pouring 70-90% of phosphoric acid with the weighed weight into a barrel according to the formula proportion, then pouring 10-20% of aluminum hydroxide and 20-40% of water into another barrel according to the formula proportion after weighing, uniformly stirring to obtain white slurry, moving the barrel containing the phosphoric acid to a lifting stirring device, slowly pouring the white slurry mixed by the aluminum hydroxide and the water while stirring, and completely pouring the white slurry to obtain the milk white slurry. The reaction heats up during stirring, and the stirring time is about 10 to 30 minutes. After the mixture is uniformly stirred and no longer performs bubbling reaction, the mixture is covered with a sealing cover, then the mixture is moved into a hot air furnace to be heated at the temperature of 150-. After cooling, the specific gravity is measured by a baume meter and is required to be 1.47-1.48 as a standard.

Preparing ceramic slurry, namely adding 10-30% of alumina, 5-10% of aluminum hydroxide, 3-6% of American kaolin (silicate kaolin) and 30-50% of silicon carbide (or corundum alumina) which are mixed according to a certain proportion into a mixing and stirring device, uniformly mixing, sieving for later use, adding the prepared sol binder into the mixed water according to a certain proportion, pouring the obtained mixture into a lifting stirring device barrel, uniformly stirring, pouring the uniformly mixed powdery raw materials into a closed lifting stirring device barrel, starting stirring at a slow speed (preventing dust rising), then stirring at a medium speed, and stirring at a high speed to form viscous ceramic slurry for later use;

preparing a three-dimensional ceramic skeleton, namely pouring ceramic slurry into a grouting machine (21) of three-dimensional ceramic skeleton automatic forming equipment as shown in figure 3; grouting, impregnation and extrusion: the three-dimensional net material A is placed on the conveying device 1, the conveying device 1 is moved to the position below the extrusion grouting device 2 to carry out a grouting, impregnation and extrusion program, and due to the fact that the extrusion device 22 is arranged behind the grouting machine 21, grouting can be carried out firstly, then the three-dimensional net material A is subjected to impregnation and extrusion, and slurry can penetrate into the three-dimensional net material A; turning over the base material: turning the multi-three-dimensional net material A sent into the turning device 3 by the conveying device 1 by one hundred eighty degrees, and enabling the bottom surface of the three-dimensional net material A, which is not subjected to impregnation grouting, on the other surface to face upwards; bottom grouting, impregnation and extrusion: the bottom surface of the three-dimensional net material A which is moved to the extrusion grouting device 2 ' from the conveying device 1 is subjected to grouting, impregnation and extrusion, and the extrusion device 22 ' is arranged behind the grouting machine 21 ', so that the three-dimensional net material A can be subjected to grouting and impregnation and extrusion, and the slurry can penetrate into the bottom surface of the three-dimensional net material A; turning over the base material: turning the three-dimensional net material A sent into the turning device 3' by the conveying device 1 by one hundred eighty degrees; extruding the base material: extruding the three-dimensional net material A which is sent into the extruding device 4 by the conveying device 1 and is impregnated and grouted on two sides, and removing redundant slurry; front blowing and sucking of the substrate: blowing and sucking the three-dimensional net material A sent into the blowing and sucking device 5 by the conveying device 1 by wind power to ensure that the slurry is uniformly distributed without blocking air holes, and the solidification of the slurry can be accelerated by blowing hot air; turning over the base material: turning the three-dimensional net material A sent into the turning device 3' by the conveying device 1 by one hundred eighty degrees to enable the bottom surface to face upwards; bottom surface blowing and sucking of the base material: blowing and sucking the three-dimensional net material A sent into the blowing and sucking device 5' by the conveying device 1 by wind power to ensure that the slurry is uniformly distributed without blocking air holes, and the solidification of the slurry can be accelerated by blowing hot air; after the smoothness of the three-dimensional pores is confirmed, moving into a continuous reaction curing program, curing the three-dimensional net material into a ceramic skeleton blank with certain strength, finally performing a heating sintering strengthening program, and cooling to obtain a three-dimensional ceramic skeleton for later use after the heating sintering strengthening;

referring to fig. 4, a three-dimensional ceramic skeleton is fixed in a metal mold B of a brake disc, an inlet airtight door 60 of a vacuum atmosphere pressurized impregnation composite forming machine 6 is opened, the metal mold B is pushed into the vacuum atmosphere pressurized impregnation composite forming machine 6, the inlet airtight door 60 is closed, a vacuum degassing operation system 62 is opened, after a vacuum set value is reached, nitrogen vacuum replacement is performed to normal pressure, an airtight door in the vacuum atmosphere pressurized impregnation composite forming machine 6 is opened, an inlet displacement system 63 pushes the metal mold B into a heating zone 61 to preheat the metal mold B, when the metal mold B is preheated, the light alloy liquid flows downwards into the metal mold B from a light alloy melting device 7 until a fixed amount is reached, the metal mold B is displaced to a gas pressurization zone 64, a nitrogen pressurization and vibration impregnation system 65 is started to perform gas pressure maintaining and vibration impregnation procedures on the metal mold B, after the solidification of the light alloy, the forced cooling system 66 is started, the airtight door in the outlet of the vacuum atmosphere pressurized impregnation composite forming machine 6 is opened, the outlet pushing system 67 pushes the metal mold B out, the airtight door in the outlet of the vacuum atmosphere pressurized impregnation composite forming machine 6 is closed, the airtight door outside the outlet 68 is opened, the outlet pushing system 67 pushes the metal mold B out of the vacuum atmosphere pressurized impregnation composite forming machine 6, the airtight door outside the outlet 68 is closed, the metal mold B is demolded, the light composite brake disc blank is taken out, and finally the light composite brake disc is manufactured through turning and milling.

The light-weight composite brake disc made of the three-dimensional ceramic framework and the composite metal base has the advantages that the three-dimensional ceramic framework is free of closed pores and is in the shape of a whole ring, the three-dimensional ceramic framework and the metal are compounded to form a continuous interface, the strength is not easy to change in the braking process due to continuous composite strength and structure, the pores of the three-dimensional ceramic framework are uniformly filled with the light alloy, and the light-weight composite brake disc has the effects of continuous composite strength, high efficiency and high quality.

Referring to fig. 2, the lightweight composite brake disc manufactured according to the method of the present invention mainly includes: the ceramic body is composed of a body 8 integrally formed by light alloy such as aluminum, aluminum magnesium or titanium and the like and two annular three-dimensional ceramic frameworks 9 with multiple pores; the center of the body is provided with an axis 80, two sides of the body are provided with friction surfaces 81 surrounding the axis 80, the two friction surfaces 81 are respectively provided with a three-dimensional ceramic framework 9 which is formed with the body, and the pores of the three-dimensional ceramic framework 9 are filled with light alloy.

The present invention further includes a support frame manufacturing process, wherein the support frame 90 is manufactured by using rigid materials such as steel plates or carbon fiber plates according to the shape of the three-dimensional ceramic skeleton, as shown in fig. 5 and 6, the contact surfaces of the upper end surface and the lower end surface of the support frame 90 and the three-dimensional ceramic skeleton 9 are provided with holes 91 and limiting portions 92, the support frame 90 is provided with an assembling hole 93 near the central end surface, when the light-weight composite brake disc is manufactured, the support frame 90 is placed between the two three-dimensional ceramic skeletons 9 and then fixed in a brake disc metal mold B to manufacture the light-weight composite brake disc, so that the light-weight composite brake disc is manufactured by combining the light-weight alloy with the support frame 90 at the center and the three-dimensional ceramic skeletons 9 at the upper and lower ends into a whole.

Referring to fig. 5 and 6, the lightweight composite brake disc manufactured according to the method of the present invention mainly includes: the ceramic body is composed of a body 8 integrally formed by light alloy such as aluminum, aluminum magnesium or titanium, two annular three-dimensional ceramic frameworks 9 with multiple pores, and a support frame 90 arranged between the two annular three-dimensional ceramic frameworks 9 with multiple pores; the center of the body 8 is provided with an axis 80, two sides of the body are provided with friction surfaces 81 surrounding the axis 80, the two friction surfaces 81 are respectively provided with a three-dimensional ceramic framework 9 which is formed with the body 8, a support frame 90 is arranged between the two three-dimensional ceramic frameworks 9, the contact surfaces of the upper end surface and the lower end surface of the support frame 90 and the three-dimensional ceramic framework 9 are provided with a hole 91 and a limiting part 92, the end surface of the support frame near the center is provided with an assembly hole 93, the space separated by the limiting part 92 and the holes of the three-dimensional ceramic framework 9 in the hole 91 of the support frame are filled with light alloy, and the support frame 90 is made of rigid material, so that the whole body of the light composite brake disc can be effectively supported, and the deformation caused by high temperature is not easy to generate.

The above-mentioned embodiments are merely preferred embodiments for fully illustrating the present invention, and the scope of the present invention is not limited thereto. The equivalent substitution or change made by the technical personnel in the technical field on the basis of the invention is all within the protection scope of the invention. The protection scope of the invention is subject to the claims.

Claims

1. A method for preparing a brake disc of a power vehicle is characterized by mainly comprising the following steps:

preparing a three-dimensional net material: foaming polyurethane polymer into foam with three-dimensional pores, cutting into preset shape, size and thickness, and performing surface treatment for later use if necessary;

preparing a binder: stirring and heating phosphoric acid or phosphate, aluminum hydroxide and water which are prepared in proportion to react to form sol for later use;

preparing ceramic slurry: uniformly mixing alumina, aluminum hydroxide, silicate kaolin and one of silicon carbide or corundum alumina which are prepared according to a certain proportion to form a powdery raw material, adding water according to a certain proportion into the prepared binder, uniformly stirring, adding the powdery raw material, and stirring to form viscous ceramic slurry for later use;

preparing a three-dimensional ceramic skeleton: pouring ceramic slurry into three-dimensional ceramic skeleton automatic molding equipment, placing a three-dimensional net material on a conveying device, performing a grouting, impregnating, extruding and absorbing slurry program, extruding and removing redundant slurry programs on the three-dimensional net material, turning the three-dimensional net material by 180 degrees, performing the grouting, impregnating, extruding and absorbing slurry program again, removing redundant slurry programs on the three-dimensional net material, performing blowing and absorbing three-dimensional net material program to enable the ceramic slurry to be uniformly distributed, transferring into a continuous reaction and solidification program after confirming three-dimensional smooth pores, solidifying the three-dimensional net material into a ceramic skeleton blank with strength, performing a sintering program, heating, sintering and strengthening, and cooling to form a three-dimensional ceramic skeleton for later use;

preparing a light alloy: heating and melting light alloy of aluminum, aluminum magnesium or titanium into light alloy soup for hot-pressing feeding;

preparing a light-weight composite brake disc: fixing the three-dimensional ceramic skeleton in a metal mold of a brake disc, pushing the metal mold into a heating zone of a vacuum atmosphere pressure impregnation composite forming machine to preheat the metal mold, after the metal mold is preheated and the light alloy soup flows downwards into the metal mold to a fixed amount, carrying out an impregnation procedure of gas pressure holding and vibration shaking on the metal mold, then carrying out a cooling procedure until the light alloy cooling time is reached, pushing out the vacuum atmosphere pressure impregnation composite forming machine, demoulding and taking out a light composite brake disc blank, and finally carrying out turning and milling to prepare the light composite brake disc.

2. The method for manufacturing a brake disc for a power vehicle according to claim 1, further comprising a manufacturing process of the support frame, wherein the support frame is manufactured by manufacturing a rigid material of a steel plate or a carbon fiber plate into a support frame according to the shape of the three-dimensional ceramic skeleton, the contact surface between the upper end surface and the lower end surface of the support frame and the three-dimensional ceramic skeleton is provided with a hole and a limiting portion, the end surface of the support frame near the center is provided with an assembly hole, and when the light-weight composite brake disc is manufactured, the support frame is placed between two pieces of the three-dimensional ceramic skeleton and then fixed in a metal mold of the brake disc to manufacture the light-weight composite brake disc, so that the light-weight composite brake disc is formed by combining the light-weight alloy, the support frame in the center and the three-dimensional ceramic skeleton at the upper and lower ends.

3. A brake disc for a power vehicle manufactured by the method for manufacturing a brake disc for a power vehicle according to claim 1, characterized by mainly comprising: is composed of a body integrally formed by light alloy of aluminum, aluminum magnesium or titanium and two pieces of three-dimensional ceramic frameworks with porous annular structures; the center of the body is provided with an axis, two sides of the body are provided with friction surfaces surrounding the axis, the two friction surfaces are respectively provided with a three-dimensional ceramic framework which is formed together with the body, and the pores of the three-dimensional ceramic framework are filled with light alloy.

4. The brake disk for a powered vehicle of claim 3, further comprising a support frame, wherein the support frame is disposed between two annular three-dimensional ceramic frames with multiple pores, the support frame is formed with the body and the three-dimensional ceramic frames, the contact surfaces of the upper end surface and the lower end surface of the support frame and the three-dimensional ceramic frames are provided with holes and limiting portions, the support frame is provided with an assembly hole near the central end surface, and the space inside the holes of the support frame and the space between the two three-dimensional ceramic frames and the pores of the three-dimensional ceramic frames are filled with light alloy.

5. The power vehicle brake disc of claim 4, wherein the support frame is constructed of a rigid material.

6. The power vehicle brake disc of claim 5, wherein the rigid material is a steel or carbon fiber plate.