CN111250698B - 一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘及其制备方法 - Google Patents
一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘及其制备方法 Download PDFInfo
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- CN111250698B CN111250698B CN202010229906.6A CN202010229906A CN111250698B CN 111250698 B CN111250698 B CN 111250698B CN 202010229906 A CN202010229906 A CN 202010229906A CN 111250698 B CN111250698 B CN 111250698B
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 98
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Abstract
本发明公开了一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘及其制备方法,轨道交通制动盘由铝基粉末冶金复合材料通过冷压成型、烧结和一体化热压整形工艺制成,制得的轨道交通制动盘具有无损伤、无缺陷、致密性好、强度高等一系列优点,能够很好地满足轨道交通制动盘的制动和耐磨要求,同时比传统铸铁制动盘减重40%~60%,极大地节省了能源消耗,符合国家节能减排的要求;且其制备方法简便,成本低,成品率高,可用于制备各尺寸及结构的轨道交通制动盘,满足工业化大批量连续生产要求。
Description
技术领域
本发明涉及一种轨道交通制动盘,具体涉及一种利用轻质耐磨的铝基粉末冶金复合材料制备的轨道交通制动盘,还涉及利用轻质耐磨铝基复合材料通过冷压成形、烧结和热压整形相结合的工艺制备轨道交通制动盘的方法,属于轨道交通制动盘制备技术领域。
背景技术
轻量化是实现轨道交通车辆节能降耗最有效的手段之一。传统交通装备发动机、制动盘等采用的为铁质金属材料,主要包括铸铁系、铸钢和锻钢等,其密度大,导热性差,易出现热龟裂等缺陷。因此采用高性能轻金属材料代替钢铁材料应用于上述关键运动零部件,不仅可减轻整车重量,降低交通装备高速运动部件的动量,更能显著改善交通装备的动力性能,同时降低能耗。高性能制动装置是发展高速列车的基础。随着高速列车快速发展,其对制动材料也提出了更高、更新的要求。制动材料必须保证在高速、高能下具有较高的摩擦性能、稳定性,以及优异的抗疲劳性能、抗热裂纹扩展能力和较高的耐磨损性能。同时,在紧急情况下,必须保证高速列车具有安全的紧急制动距离。目前,纯空气盘形制动是300km/h等级的高速列车实施安全制动的最重要的手段。高铁制动盘属于簧下质量,其质量几乎占整个转向架的20%,制动盘的轻量化有助于提高转向架的动力学品质,减少牵引能耗。日本新干线的试验结果表明,将轴重由16吨减少到11.3吨,可减少34%的运行成本。因此,制备轻量化轨道交通制动盘已成为迫切需要解决的问题。
铝基复合材料具有密度小、比强度高、热稳定性好、导热性能好等一系列优势,是支撑《中国制造2025》、实现环境友好型社会及节能降耗的重要材料,也是重点应用领域急需的新材料。以此作为轨道交通制动盘的材料,可大大降低其重量,达到节能减排的效果。但单纯的颗粒增强铝基复合材料较软,难以满足汽车多变工况下的刹车磨损要求,因此在其中添加其他合金元素及微量元素以及提高增强体陶瓷颗粒含量有望改善这一情况。德国率先开展了铝基复合材料制动盘的研究,据报道每个制动盘的质量已从115kg减少到了65kg,但其使用的为铸造法,难以避免铸造过程中产生气孔、缺陷等问题,同时该方法限制了铝基复合材料中陶瓷颗粒含量的上限,使其含量只能在20%以下,导致其机械性能难以大幅提高,难以满足更高速度列车的制动要求。日本、法国也开展了对铝基复合材料制动盘的研究,但都尚处于研究与试验阶段。而国内在此领域的研究基本上还是空白。其难点是轨道交通制动盘尺寸极大,采用传统制备工艺制造在组织和性能上难以达到使用要求。传统粉末冶金法虽可提高陶瓷颗粒含量,达到使用要求,却无法制备这样尺寸较大、结构复杂的产品,极易产生开裂。因此利用粉末冶金的原理,通过工艺和参数的创新和改进,有望制备得到符合要求的陶瓷颗粒增强铝基复合材料轨道交通制动盘。
发明内容
针对轨道交通装备轻量化的趋势和现有轨道交通制动盘制备技术存在的缺陷,本发明的目的是在于提供一种轻质、耐磨的铝基复合材料轨道交通制动盘,解决了传统铸铁制动盘能耗大、不利于环保的问题,以及纯铝基粉末冶金复合材料制动盘不耐磨,达不到制动要求的难题。
本发明的另一个目的是在于提供一种通过冷压成形、烧结和热压整形相结合的工艺制备轨道交通制动盘的方法,该方法制备的轨道交通制动盘具有轻量化以及优异的耐磨性能和制动性能,可广泛用于制造各种轨道交通制动***,并解决了制动盘中陶瓷颗粒含量难以突破上限,以及制备成型过程中易产生气孔、开裂的难题。
为了实现上述技术目的,本发明提供了一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘,其由耐磨铝基复合材料构成;所述耐磨铝基复合材料由铝粉、主要合金元素、微量元素和陶瓷颗粒四者组成;所述主要合金元素为Cu、Si、Fe、Ni、Mg中至少一种;所述微量元素为Sr、Ce、Sn中至少一种。
优选的方案,所述耐磨铝基复合材料的质量百分比组成:主要合金元素3~12%(每种主要合金元素的质量分数在0.2~12%范围内可调);微量元素不大于1.5%(每种微量元素的质量分数在0~1.5%范围内可调);陶瓷颗粒20~75%(每种陶瓷颗粒的质量分数在20~75%的范围内可调);铝粉,余量,(以铝粉、主要合金元素、微量元素和陶瓷颗粒总质量为100%计量)。
本发明的技术方案中提出在铝基复合材料中引入适量的Cu、Si、Fe、Ni、Mg等合金元素,通过控制化学成份和烧结制度,上述合金元素在烧结过程中可在内部产生液相体促进烧结,并原位生成以这些元素为主的二元或多元的细小金属间化合物强化相,起到强化铝基复合材料的机械性能的作用,改善其耐磨性能。质量分数对强化效果起到重要作用,若质量分数低于优选的范围,起不到强化效果;若质量分数过大,高于优选的范围,非但无法形成上述金属间化合物、提高耐磨性能,而且会增加制动盘质量,达不到减重效果。
本发明的技术方案还提出在铝基复合材料中加入少量的Sr、Ce、Sn等微量元素,少量微量元素可促进合金元素形成金属间化合物,但若微量元素含量过高,会生成其他的金属间化合物杂质,影响其性能。
优选的方案,所述陶瓷颗粒为SiC、Al2O3、Si3N4中至少一种。
本发明技术方案在铝基复合材料中引入SiC、Al2O3、Si3N4陶瓷颗粒,这些陶瓷颗粒具有极高的强度和优异的耐高温性能,一直是复合材料增强体的首选,可大幅度提高复合材料的综合性能,且含量越高,增强效果越显著。但由于现有制备方法限制,一直无法突破制动盘中由于陶瓷与铝合金浸润性不佳,导致的陶瓷颗粒含量不能过高、综合性能较差的难题。本发明技术方案采用冷压成形、烧结和热压整形相结合的工艺,提高了陶瓷颗粒的含量上限,如陶瓷颗粒质量百分比含量可以高于20%,优选高于40%,甚至高于60%,最高可以达到75%,进一步提高了制动盘的耐磨性能。
本发明还提供了一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备方法,其包括以下步骤:
1)将耐磨铝基复合材料混合粉体填充至环盘形模具中,在室温下冷压成形,脱模,得到轨道交通制动盘坯体;
2)将轨道交通制动盘坯体进行烧结成型,得到轨道交通制动盘前体;
3)将轨道交通制动盘前体置于热压整形模具中压制整形,得到轨道交通制动盘粗制体;
4)将轨道交通制动盘粗制体经过机加工,即得。
优选的方案,所述冷压成形的条件为:压力为150~300MPa,加压速率为1~5mm/s,保压时间为3~10s。将耐磨铝基复合材料混合粉体填入超大型环盘形模具中,合模并排气后,在室温下冷压成形。成型后的轨道交通制动盘坯体粉体结合良好,为超大型环盘形坯体。其外直径可达到600~900mm,内直径达200~450mm,高可达20~140mm。冷压后坯体形状如图1。冷压成型模具如图2,模具内部根据坯体形状进行常规设计。
优选的方案,所述烧结成型过程包括除蜡、烧结和冷却。
优选的方案,所述烧结成型过程条件为:在氮气保护下,以8~15℃/min加热速率,先升温至350℃~450℃,保温15~30min,再升温至580℃~620℃,保温25~45min,最后降温至500℃以下。较优选的条件:氮气中氧的含量要小于10PPM,露点温度低于-40℃。本发明的技术方案中首次提出铝基粉末冶金复合材料制动盘烧结温度曲线,其目的是为了使坯体温度达到液相线附近,并随炉缓慢冷却至固相线附近,从而提高坯体的塑性,同时去除由于烧结和冷却产生的内部应力,确保了超大尺寸制动盘坯体的无缺陷成形。
优选的方案,所述压制整形为“一体化热压整形”,其条件为:压制温度为500℃~600℃,压力为150~300MPa,加压速率为1~5mm/s,保压时间为5~30s。压制整形后的制动盘粗制体具有接近净尺寸的外形及完整散热筋结构。热压模具如图3所示,上模如图4所示。常规粉末冶金制品并无热压整形工艺,本发明的技术方案中首次提出在轨道交通制动盘制备中加入上述“一体化热压整形”工艺并使用上述参数,一方面可以进一步增加汽车制动盘前体的致密性,从而全面提高制动盘的机械性能,特别是耐磨损性能和材料的刚度,另一方面可直接压制出复杂的散热筋形状,通过参数的控制,保证散热筋结构完整,不出现缺角、裂纹等缺陷,并调节制动盘坯体外形尺寸,使其更接近净尺寸,同时也可以修复冷压和烧结过程中可能出现的缺陷,提高成品率。
优选的方案,所述机加工包括去毛刺、飞边及表面氧化层。所述机加工工艺为粗车。
优选的方案,得到的轻质耐磨铝基粉末冶金复合材料轨道交通制动盘密度为2.60~2.95g/cm3。
优选的方案,耐磨铝基复合材料混合粉体的制备:将铝粉、主要合金元素、微量元素和陶瓷颗粒等放入混料机中进行混合,混料机转速为15~35r/min,混料时间为35~60min。
本发明技术方案提供的新型轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备工艺。一方面,基于调整铝基粉末冶金复合材料成分,提高其耐磨性能、综合机械性能和机加工性能,使其能够满足轨道交通制动盘的制动需求的同时有较低的重量,另一方面,利用粉末冶金原理,通过冷压成型、烧结和一体化热压整形工艺及其参数的控制,得到接近净尺寸且无缺陷的各型轨道交通制动盘。
本发明涉及的模具可以根据现有轨道交通制动盘的形状常规设计。
相对现有技术,本发明技术方案带来的有益技术效果:
1)本发明得到的铝基粉末冶金轨道交通制动盘大大降低了制动盘的重量,同时具有耐磨性能和制动性能好、致密性好、无气孔及裂纹的优点,可在满足轨道交通车辆制动要求的同时大大降低能耗,起到节能减排的效果,其密度为2.60~2.95g/cm3,硬度在60HRB以上,拉伸强度高于230MPa,可广泛适用于各种轨道交通车辆制动***。
2)本发明的轨道交通制动盘所用材料,通过引入大量陶瓷颗粒和细小的金属间化合物,形成Al-颗粒强化相,从而大大提高了铝基复合材料的机械性能,特别是耐磨损性能和材料的刚度。
3)本发明的铝基粉末冶金复合材料轨道交通制动盘制备过程采用粉末冶金原理,突破了铝基粉末冶金轨道交通制动盘中陶瓷颗粒的含量上限,使其质量分数最高可达到75%,大大提升了制动盘的强度和耐磨性能。
4)本发明的铝基粉末冶金复合材料轨道交通制动盘制备过程通过增加一体化热压整形工艺及控制冷压、烧结和热压整形工艺的参数,得到了具有超大尺寸的轨道交通制动盘,其外直径可达到600~900mm,内直径达200~450mm,高可达20~140mm。且制动盘内部致密、无气孔及裂纹、接近净尺寸且有完整散热筋结构,大大节省了后续机加工成本。
5)本发明的铝基粉末冶金复合材料轨道交通制动盘制备过程工序少、操作简便、成本低、成品率高,且可应用于各种形状的轨道交通制动盘的制备,可进行工业化大批量连续生产。
附图说明
【图1】冷压后坯体形状示意图。
【图2】为冷压成型模具。
【图3】为热压整形模具内部结构图。
【图4】为热压整形模具上模图。
【图5】为Al-40%SiC复合材料汽车制动盘的显微结构图。
【图6】为铝基粉末冶金复合材料汽车制动盘实物图。
【图7】为未经过热压整形的铝基粉末冶金复合材料轨道交通制动盘照片。
具体实施方案
以下实施例旨在进一步说明本发明内容,而不是限制权利要求的保护范围。
实施例1
本实施方式的一种铝基粉末冶金复合材料轨道交通制动盘制备方法,按照下列各步骤实施:一、将4.5%的Cu、3.5%的Mg、1.5%的Si、0.2%的Sr、0.3%的Ce、30%的SiC及60%的铝粉(以上均为质量分数)加入混料机,以20r/min的速度混合60min,得到耐磨铝基复合材料粉体;二、将步骤一处理的耐磨铝基复合材料粉体填入冷压模具中,进行冷压,压力为200MPa,加压速率为2mm/s,保压时间为8s;三、将步骤二处理的轨道交通制动盘坯体在氮气保护下进行烧结(一般氮气中氧的含量小于10PPM,露点温度低于-40℃),以10℃/min加热速率,先升温至450℃,保温20min,再升温至620℃,保温30min,最后降温至490℃;四、将步骤三处理的轨道交通制动盘前体放入热压模具中,进行压制整形,压制温度为530℃,压力为200MPa,加压速率为3mm/s,保压时间为20s;五、将步骤四处理的轨道交通制动盘粗制体进行粗车,去除毛刺、飞边及表面氧化层,即完成铝基粉末冶金复合材料轨道交通制动盘的制备。
经检测,通过该方法制备的铝基粉末冶金复合材料轨道交通制动盘的密度为2.79g/cm3,硬度为87HRB,同时具有较低的密度和力学性能,轻量化效果明显。图5为该Al-30%复合材料汽车制动盘的扫描电镜显微结构图,由图可见制动盘内部致密,无气孔及细小裂纹,且颗粒分布均匀。图6为该铝基粉末冶金复合材料轨道交通制动盘照片,可见制动盘外部无开裂及缺陷。
实施例2
本实施方式的一种铝基粉末冶金复合材料轨道交通制动盘制备方法,按照下列各步骤实施:一、将5%的Fe、2%的Mg、1%的Ni、0.5%的Ce、40%的SiC及51.5%的铝粉(以上均为质量分数)加入混料机,以20r/min的速度混合50min,得到耐磨铝基复合材料粉体;二、将步骤一处理的耐磨铝基复合材料粉体填入冷压模具中,进行冷压,压力为250MPa,加压速率为2mm/s,保压时间为10s;三、将步骤二处理的轨道交通制动盘坯体在氮气保护下进行烧结(一般氮气中氧的含量小于10PPM,露点温度低于-40℃),以10℃/min加热速率,先升温至460℃,保温20min,再升温至600℃,保温30min,最后降温至490℃;四、将步骤三处理的轨道交通制动盘前体放入热压模具中,进行压制整形,压制温度为550℃,压力为200MPa,加压速率为3mm/s,保压时间为20s;五、将步骤四处理的轨道交通制动盘粗制体进行粗车,去除毛刺、飞边及表面氧化层,即完成铝基粉末冶金复合材料轨道交通制动盘的制备。
经检测,通过该方法制备的铝基粉末冶金复合材料轨道交通制动盘的机械性能如表1所示。可见材料具有优异的抗拉强度和延伸率,刚性和塑性性能都有所增强。
表1铝基粉末冶金复合材料轨道交通制动盘的机械性能
实施例3
本实施方式的一种铝基粉末冶金复合材料轨道交通制动盘制备方法,按照下列各步骤实施:一、将5%的Si、5%的Fe、0.5%的Ce、0.5%的Sn、60%的SiC及29%的铝粉(以上均为质量分数)加入混料机,以20r/min的速度混合50min,得到耐磨铝基复合材料粉体;二、将步骤一处理的耐磨铝基复合材料粉体填入冷压模具中,进行冷压,压力为250MPa,加压速率为2mm/s,保压时间为10s;三、将步骤二处理的轨道交通制动盘坯体在氮气保护下进行烧结(一般氮气中氧的含量小于10PPM,露点温度低于-40℃),以10℃/min加热速率,先升温至460℃,保温20min,再升温至600℃,保温30min,最后降温至490℃;四、将步骤三处理的轨道交通制动盘前体放入热压模具中,进行压制整形,压制温度为550℃,压力为200MPa,加压速率为3mm/s,保压时间为20s;五、将步骤四处理的轨道交通制动盘粗制体进行粗车,去除毛刺、飞边及表面氧化层,即完成铝基粉末冶金复合材料轨道交通制动盘的制备。
经检测,通过该方法制备的铝基粉末冶金复合材料轨道交通制动盘的机械性能如表2所示。可见材料具有优异的抗拉强度和延伸率,刚性和塑性性能都有所增强。
表2铝基粉末冶金复合材料轨道交通制动盘的机械性能
实施例4
本实施方式的一种铝基粉末冶金复合材料轨道交通制动盘制备方法,按照下列各步骤实施:一、将1%的Fe、2%的Mg、2%的Ni、5%的Si、0.3%的Ce、0.4%的Sn、0.3%的Sr、55%的SiC及34%的铝粉(以上均为质量分数)加入混料机,以20r/min的速度混合50min,得到耐磨铝基复合材料粉体;二、将步骤一处理的耐磨铝基复合材料粉体填入冷压模具中,进行冷压,压力为300MPa,加压速率为2mm/s,保压时间为10s;三、将步骤二处理的轨道交通制动盘坯体在氮气保护下进行烧结(一般氮气中氧的含量小于10PPM,露点温度低于-40℃),以10℃/min加热速率,先升温至460℃,保温20min,再升温至600℃,保温30min,最后降温至490℃;四、将步骤三处理的轨道交通制动盘前体放入热压模具中,进行压制整形,压制温度为550℃,压力为300MPa,加压速率为3mm/s,保压时间为20s;五、将步骤四处理的轨道交通制动盘粗制体进行粗车,去除毛刺、飞边及表面氧化层,即完成铝基粉末冶金复合材料轨道交通制动盘的制备。
经检测,通过该方法制备的铝基粉末冶金复合材料轨道交通制动盘的机械性能如表3所示。可见材料具有优异的抗拉强度和延伸率,刚性和塑性性能都有所增强。
表3铝基粉末冶金复合材料轨道交通制动盘的机械性能
对比实施例1
对比实施例1为未加入合金元素的轨道交通制动盘的制备方法,按照下列各步骤实施:一、将5%的Fe、2%的Mg、1%的Ni、40%的SiC及52%的铝粉(以上均为质量分数)加入混料机,以20r/min的速度混合50min,得到耐磨铝基复合材料粉体;二、将步骤一处理的耐磨铝基复合材料粉体填入冷压模具中,进行冷压,压力为250MPa,加压速率为2mm/s,保压时间为10s;三、将步骤二处理的轨道交通制动盘坯体在氮气保护下进行烧结(一般氮气中氧的含量小于10PPM,露点温度低于-40℃),以10℃/min加热速率,先升温至460℃,保温20min,再升温至600℃,保温30min,最后降温至490℃;四、将步骤三处理的轨道交通制动盘前体放入热压模具中,进行压制整形,压制温度为550℃,压力为200MPa,加压速率为3mm/s,保压时间为20s;五、将步骤四处理的轨道交通制动盘粗制体进行粗车,去除毛刺、飞边及表面氧化层,即完成铝基粉末冶金复合材料轨道交通制动盘的制备。
经检测,通过该方法制备的铝基粉末冶金复合材料轨道交通制动盘的机械性能见表4。与实施例2中制动盘的性能对比,其强度和硬度都有大幅度下降,塑性性能也极差,无法达到制动盘的强度和摩擦要求。
表4铝基粉末冶金复合材料轨道交通制动盘的机械性能
对比实施例2
对比实施例2为未经压制整形的轨道交通制动盘的制备方法,按照下列各步骤实施:一、将4.5%的Cu、3.5%的Mg、1.5%的Si、0.2%的Sr、0.3%的Ce、30%的SiC及60%的铝粉(以上均为质量分数)加入混料机,以20r/min的速度混合60min,得到耐磨铝基复合材料粉体;二、将步骤一处理的耐磨铝基复合材料粉体填入冷压模具中,进行冷压,压力为200MPa,加压速率为2mm/s,保压时间为8s;三、将步骤二处理的轨道交通制动盘坯体在氮气保护下进行烧结(一般氮气中氧的含量小于10PPM,露点温度低于-40℃),以10℃/min加热速率,先升温至450℃,保温20min,再升温至620℃,保温30min,最后降温至490℃;四、将步骤三处理的轨道交通制动盘粗制体进行粗车,去除毛刺、飞边及表面氧化层,即完成铝基粉末冶金复合材料轨道交通制动盘的制备。
图7为未经压制整形的轨道交通制动盘的照片,可见盘体开裂严重,内部粉体结合效果差,完全不符合要求。
Claims (8)
1.一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘,其特征在于:由耐磨铝基复合材料构成;所述耐磨铝基复合材料由铝粉、主要合金元素、微量元素和陶瓷颗粒四者组成;所述主要合金元素为Cu、Si、Fe、Ni、Mg中至少一种;所述微量元素为Sr、Ce、Sn中至少一种;
所述耐磨铝基复合材料的质量百分比组成:
主要合金元素3~12%;
微量元素不大于1.5%;
陶瓷颗粒>30%且≤75%;
铝粉,余量;所述陶瓷颗粒为碳化硅。
2.权利要求1所述的一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备方法,其特征在于:包括以下步骤:
1)将耐磨铝基复合材料混合粉体填充至环盘形模具中,在室温下冷压成形,脱模,得到轨道交通制动盘坯体;
2)将轨道交通制动盘坯体进行烧结成型,得到轨道交通制动盘前体;
3)将轨道交通制动盘前体置于热压整形模具中压制整形,得到轨道交通制动盘粗制体;
4)将轨道交通制动盘粗制体经过机加工,即得。
3.根据权利要求2所述的一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备方法,其特征在于:所述冷压成形的条件为:压力为150~300MPa,加压速率为1~5 mm/s,保压时间为3~10 s。
4.根据权利要求3所述的一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备方法,其特征在于:所述烧结成型过程包括除蜡、烧结和冷却。
5.根据权利要求2或4所述的一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备方法,其特征在于:所述烧结成型过程条件为:在氮气保护下,以8~15℃/min加热速率,先升温至350℃~450℃,保温15~30 min,再升温至580℃~620℃,保温25~45 min,最后降温至500℃以下。
6.根据权利要求2所述的一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备方法,其特征在于:所述压制整形的条件:压制温度为 500℃~600℃,压力为150~300 MPa,加压速率为1~5 mm/s,保压时间为5~30 s。
7.根据权利要求2所述的一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备方法,其特征在于:所述机加工包括去毛刺、飞边及表面氧化层。
8.根据权利要求2所述的一种轻质耐磨铝基粉末冶金复合材料轨道交通制动盘的制备方法,其特征在于:得到的轻质耐磨铝基粉末冶金复合材料轨道交通制动盘密度为2.60~2.95 g/cm3。
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