CN111853117A - 一种高性能粉末冶金摩擦闸片材料及制备方法 - Google Patents
一种高性能粉末冶金摩擦闸片材料及制备方法 Download PDFInfo
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Abstract
制动闸片是高速列车制动***的关键执行部件,通过制动闸片和制动盘的摩擦将列车动能转化为摩擦热能,实现列车减速最终停车,确保高速列车的安全运行。随着列车运营速度的不断提升,对制动闸片材料提出了更高的要求。本发明设计了一种高性能粉末冶金摩擦闸片材料,先制备成分为C:1.8‑2.2%,Cr:3.5‑4.0%,Mo:2.2‑2.5%,V:4.5‑5.0%,W:10‑14%,Co:7‑8%,余量为Fe的合金粉末,然后根据列车时速选取合适的粒度进行压制成形,并烧结成具有一定强度和孔隙率的多孔体,然后将多孔体熔渗铜得到致密的块体材料,再通过合适的热处理最终得到高性能的粉末冶金摩擦闸片材料,该材料兼顾粉末冶金铁基和铜基摩擦材料的优点,克服单一材料的缺点,因此具有优异的综合性能。
Description
技术领域
本发明涉及闸片材料技术领域,特别是指一种高性能粉末冶金摩擦闸片材料及制备方法。
背景技术
随着列车向高速化发展,原有的200~350km/h高速列车使用的铜基复合材料制动闸片配方由于设计的平均摩擦因数低,材料承受的最高使用温度较低,难以满足350km/h及以上高速列车的使用要求。摩擦闸片或刹车片重要的性能指标之一是摩擦系数。国家标准规定的刹车摩擦系数在0.35-0.40之间,同时合格的刹车片摩擦系数应适中、稳定,如果摩擦系数低于0.35,刹车时就会超过安全制动距离甚至刹车失灵,如果摩擦系数高于0.40,刹车容易突然抱死,出现翻车事故。随着列车时速的增加,除了对摩擦闸片的摩擦系数有要求外,还要求闸片具有较高的强度。目前车辆用的粉末冶金摩擦材料主要有铁基和铜基两大类,其中铁基摩擦材料耐热性好,强度高,但是摩擦因数大(=0.4~0.55),同时易与对偶件表面发生粘着,另外摩擦因数的稳定性也不如铜基摩擦材料的,而目前高速列车广泛应用的铜基复合材料摩擦闸片的导热性好,摩擦因数较稳定,耐磨性较好,但是耐高温性能差。因此,随着列车时速的不断增加,急需开发出一种耐热性能好、导热性能好、摩擦系数适中、与对偶制动盘不易发生粘着和破坏的粉末冶金摩擦材料。
发明内容
本发明针对目前铁基和铜基粉末冶金摩擦材料存在的问题,并结合高速列车对高性能摩擦闸片的性能要求,设计了一种新的粉末冶金摩擦闸片材料,该材料兼顾铁基和铜基摩擦材料的优点,具有摩擦系数稳定、耐高温强度高、耐磨性能好,对制动盘损伤小,导热性能好等优异的综合性能。具体的发明内容为:
(1)首先采用气雾化技术制备合金粉末,其成分(质量百分比)为C:1.8-2.2%,Cr:3.5-4.0%,Mo:2.2-2.5%,V:4.5-5.0%,W:10-14%,Co:7-8%,余量为Fe。
(2)第二步,对上述成分的合金粉末进行筛分,然后选用粒度为5-10微米和25-50微米的合金粉末压制成形,压制压力80-100MPa,其中5-10微米主要用于时速小于350公里/小时的列车用摩擦闸片,25-50微米主要用于时速大于350公里/小时的列车用闸片。
(3)第三步,将压制坯体于氢气氛中进行烧结,烧结温度为1220-1250℃,保温时间25-30分钟,得到合金多孔体。
(4)第四步,将烧结多孔体置于真空压力熔渗炉中进行渗铜,其中熔渗之前先将多孔体预热,预热温度为1000-1020℃,预热时间为40-60分钟,预热的同时将铜进行融化,融化的温度为1200-1250℃,然后进行压力熔渗操作,熔融的铜在压力作用下会快速渗入到烧结多孔体的孔隙中,熔渗加压压力为2-4MPa,熔渗保温保压时间为5-10分钟,然后随炉冷却到500℃以下出炉。
(5)第五步,将熔渗得到的致密材料进行热处理,热处理工艺为,首先将材料加热到900-950℃,保温时间为60-90分钟,然后油淬到室温,再将淬火后的材料进行高温回火处理,回火温度为620-650℃,回火保温时间60-90分钟,回火后即得到成品粉末冶金摩擦闸片。
本发明的优点在于:(1)先制备多孔铁基合金骨架,然后熔渗铜,可以形成双连通的结构,其中连通的多孔合金可提供高的耐高温强度和耐磨性能,铜可提供高的导热性能和抗粘着性能,减少纯铁基合金对制动盘的损伤,使得所制备的材料最终兼顾粉末冶金铁基和铜基摩擦材料的优点,克服单一材料的缺点;(2)所设计的铁基合金材料通过成分设计以及热处理可析出弥散的(V,W)C、Fe3W3C、Fe3Mo3C、Cr7C3等多种碳化物硬质相,其尺寸在1-2微米,可以保证合金具有优异的耐磨性能和耐高温强度,另外即使在摩擦的过程中硬质相颗粒脱落,由于其尺寸较小,也不会对制动盘表面有损伤;(3)本发明设计的合金成分粉末烧结温度低,烧结过程中会产生部分液相,因此烧结强度高,烧结后连通性能好,这可以进一步保证最终材料具有优异的耐高温强度和耐磨性能;(4)本发明可以通过调整多孔体合金粉末的粒度来间接对铜的含量进行调整,粒度越细,压制后多孔体的孔隙越多,对应的铜含量也越高,粒度越粗,压制后多孔体的孔隙越少,对应的铜含量也越少,铜含量高时合金的耐高温性能差,因此适合低速列车,铜含量低时材料的耐高温性能好,因此适合高速列车;(5)本发明的材料成分简单,无需传统摩擦材料所需要的多组元成分设计,同时仅需要通过调整合金粉末的粒度来间接对最终的性能进行调控,从而适用不同速度的列车,因此工艺控制更简单,成本更低,同时综合性能优于目前的粉末冶金摩擦材料;(6)本发明的摩擦材料,除了适用于高速列车,也适用用作重型车辆的摩擦刹车片。
具体实施方式:
(1)制备时速小于350公里/小时的列车用摩擦闸片材料首先采用气雾化技术制备合金粉末,其成分(质量百分比)为C:2%,Cr:3.7%,Mo:2.3%,V:4.7%,W:12%,Co:7%,余量为Fe;第二步,将制备的合金粉末进行筛分,然后选用粒度为5-10微米的合金粉末压制成形,压制压力80MPa;第三步,将压制坯体于氢气氛中进行烧结,烧结温度为1230℃,保温时间25分钟,得到合金多孔体;第四步,将烧结多孔体置于真空压力熔渗炉中进行渗铜,熔渗之前先将多孔体于1000℃预热40分钟,预热的同时将铜进行融化,融化的温度为1200℃,然后进行压力熔渗,熔渗加压压力为3MPa,熔渗保温保压时间为10分钟,然后随炉冷却到500℃以下出炉;第五步,将熔渗得到的致密材料进行热处理,首先将材料加热到900℃,保温时间为60分钟,然后油淬到室温,再将淬火后的材料进行高温回火处理,回火温度为620℃,回火保温时间60分钟,回火后即得到成品粉末冶金摩擦闸片。
(2)制备时速高于350公里/小时的列车用摩擦闸片材料
首先采用气雾化技术制备合金粉末,其成分(质量百分比)为C:2.2%,Cr:4.0%,Mo:2.2%,V:4.5%,W:10%,Co:8%。第二步,选用粒度为25-50微米的合金粉末压制成形,压制压力100MPa;第三步,将压制坯体于氢气氛中1250℃烧结30分钟,得到合金多孔体;第四步,将烧结多孔体置于真空压力熔渗炉中进行渗铜,其中熔渗之前先将多孔体预热,预热温度为1020℃,预热时间为60分钟,预热的同时将铜进行融化,融化的温度为1250℃,然后进行压力熔渗,熔渗加压压力为4MPa,熔渗保温保压时间为10分钟,然后随炉冷却到500℃以下出炉;第五步,将熔渗得到的致密材料进行热处理,首先将材料加热到950℃,保温时间为90分钟,然后油淬到室温,再将淬火后的材料进行高温回火处理,回火温度为650℃,回火保温时间90分钟,回火后即得到成品粉末冶金摩擦闸片。
Claims (1)
1.一种高性能粉末冶金摩擦材料,其特征在于:(1)首先采用气雾化技术制备合金粉末,其成分(质量百分比)为C:1.8-2.2%,Cr:3.5-4.0%,Mo:2.2-2.5%,V:4.5-5.0%,W:10-14%,Co:7-8%,余量为Fe;
(2)第二步,对上述成分的合金粉末进行筛分,然后选用粒度为5-10微米和25-50微米的合金粉末压制成形,压制压力80-100MPa,其中5-10微米主要用于时速小于350公里/小时的列车用摩擦闸片,25-50微米主要用于时速大于350公里/小时的列车用闸片;
(3)第三步,将压制坯体于氢气氛中进行烧结,烧结温度为1220-1250℃,保温时间25-30分钟,得到合金多孔体;
(4)第四步,将烧结多孔体置于真空压力熔渗炉中进行渗铜,其中熔渗之前先将多孔体预热,预热温度为1000-1020℃,预热时间为40-60分钟,预热的同时将铜进行融化,融化的温度为1200-1250℃,预热完成后将熔融的铜浇铸到多孔体上方,进行压力熔渗操作,熔融的铜在压力作用下会快速渗入到烧结多孔体的孔隙中,熔渗加压压力为2-4MPa,熔渗保温保压时间为5-10分钟,然后随炉冷却到500℃以下出炉;
(5)第五步,将熔渗得到的致密材料进行热处理,热处理工艺为,首先将材料加热到900-950℃,保温时间为60-90分钟,然后油淬到室温,再将淬火后的材料进行高温回火处理,回火温度为620-650℃,回火保温时间60-90分钟,回火后即得到成品粉末冶金摩擦闸片。
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