CN111978093A - 高温碳基刹车盘及其制作方法 - Google Patents
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Abstract
本发明公开了一种高温碳基刹车盘及其制作方法,刹车盘包括碳纤维和基质,两个侧面形成第一摩擦面和第二摩擦面,碳纤维沿刹车盘轴向分布,与摩擦面垂直,基质为C/C‑SiC‑Si3N4复合材料基质。制作方法包括以下步骤:(1)制备胶膜;(2)制备酚醛碳纤维预浸料;(3)制备碳纤维管筒;(4)碳纤维管筒固化;(5)分切;(6)碳化;(7)精加工。本发明利用酚醛树酯、聚碳硅烷和聚氮硅烷制成胶膜,胶膜与碳纤维原布制备得到的酚醛碳纤维预浸料,利用该预浸料制成碳纤维管筒,固化分切后的毛坯体高温碳化,酚醛树脂碳化形成树脂碳,聚碳硅烷碳化成碳化硅,聚氮硅烷转化为氮化硅得到C/C‑SiC‑Si3N4复合材料刹车盘,该刹车盘性能可靠,加工工艺简单、生产周期短、成本低。
Description
技术领域
本发明涉及刹车盘制造技术领域,尤其涉及一种高温碳基刹车盘及其制作方法。
背景技术
目前广泛应用于高速列车、赛车和飞机上的刹车材料主要采用粉末冶金材料和碳碳复合材料。碳-碳复合材料制造的刹车较钢刹车来说,具有重量轻、耐磨损、比热高、高温不粘接等优点。但是传统碳基刹车盘制作方法中采用CVD气相沉积法制得碳坯体,碳坯体的制备由多层碳纤维布层经过针刺制成网胎碳坯体。在使用过程中,刹车盘摩擦面出现不等量摩擦,造成刹车盘表面不平整,大量纤维残存,导致刹车时车体抖动以及动平衡无法保持,另外通过CVD气相沉积法生产周期长,制约其发展。中国专利申请CN 105697614A一种飞机碳-碳复合材料刹车盘及其制作方法,飞机碳-碳复合材料碳刹车盘由碳纤维布或聚丙烯腈碳纤维毡或将碳纤维布和碳纤维毡叠在一起的复合层连续周向卷绕,以及径向贯穿该卷绕层的碳纤维线和碳质基体复合构成,通过增密工艺和随后处理得到飞机碳-碳复合材料刹车盘。碳盘的纤维取向,既有平行摩擦面的,又有垂直摩擦面的,或与摩擦面成一定角度的,有利于稳定和改善摩擦磨损性能。这种刹车片改变传统碳布平面叠层碳盘纤维均处于平行摩擦面的状态,具有使用寿命较长、碳盘综合性能较好的特点。但该刹车盘制作中其致密化采用单一的浸渍法,或CVD法工艺,或浸渍法与CVD法并用的复合工艺增密,其生产加工时间相对较长,成本高。
发明内容
本发明的目的是提供一种加工工艺简单、使用性能好的高温碳基刹车盘及其制作方法。
本发明采用本发明解决其技术问题所采用的技术方案是:高温碳基刹车盘,所述刹车盘包括碳纤维和基质,所述刹车盘的两个侧面形成第一摩擦面和第二摩擦面,所述碳纤维包括垂直碳纤维,垂直碳纤维沿刹车盘轴向分布,与摩擦面垂直,所述基质为C/C-SiC-Si3N4复合材料基质。
所述基质为酚醛树酯、聚碳硅烷和聚氮硅烷按重量比100:(2-8):(1-3)配比,在高温下碳化得到的C/C-SiC-Si3N4复合材料基质。
一种高温碳基刹车盘的制作方法,包括以下步骤:
(1)制备胶膜;酚醛树酯、聚碳硅烷和聚氮硅烷按重量比100:(2-8):(1-3)的比例制得胶膜,胶膜克重200-220g/㎡。所述酚醛树酯树脂残存率为45%以上,并且游离基小于0.02。
(2)制备酚醛碳纤维预浸料;用胶膜与碳纤维原布制得预浸料,酚醛树脂与预浸料的重量比33%-45%,碳纤维零度方向排布与胶膜粘合,制得单向碳纤维预浸料。
(3)制备碳纤维管筒;以刹车盘内径大小制成模具芯模,按照刹车盘的外径尺寸将步骤(2)中的酚醛碳纤维预浸料高压卷缠在模具芯模上,并沿管筒环向用碳纤维进行绗缝制得碳纤维管筒。所述绗缝用人字纹绗缝,呈现±45°的交叉结构。
(4)碳纤维管筒固化;将步骤(3)得到碳纤维管筒进行加热固化,固化后脱模。
(5)分切;将固化的碳纤维管筒按照刹车盘坯体厚度要求进行横截面分切得到刹车盘毛坯体。
(6)碳化;毛坯体放入碳化炉中进行碳化,碳化炉温度1200℃,无氧环境。
(7)精加工,将碳化的刹车盘半成品进行机械加工制得高温碳基刹车盘成品。
本发明的有益效果是:改变传统碳基刹车盘制作方法,利用酚醛树酯、聚碳硅烷和聚氮硅烷制成胶膜,用胶膜与碳纤维原布制备得到的酚醛碳纤维预浸料卷缠在模具芯模上形成碳纤维管筒,该碳纤维管筒环向绗缝增强管筒层间的连接强度,并提供不同走向的摩擦纤维,固化的碳纤维管筒可按照刹车盘的厚度要求进行分切,分切后毛坯体高温碳化,由于酚醛树脂含有大量苯环,高温下可以碳化形成石墨化层和碳化层,形成树脂碳,聚碳硅烷碳化成碳化硅,聚氮硅烷是作为陶瓷相的一种原料,通过浸渍工艺进入碳坯体后通过高温裂解转化为氮化硅陶瓷材料,得到刹车盘为C/C-SiC-Si3N4复合材料刹车盘,并且该刹车盘以横切端面作为摩擦面,碳纤维与横切断面的角度为90°,其摩擦性能好,生产周期仅需要7天,大大缩短了碳基刹车盘生产周期和生产成本。
附图说明
图1本发明高温碳基刹车盘结构示意图。
图2为图1中A-A剖视图。
图3为绗缝结构示意图。
图中,1第一摩擦面,2第二摩擦面,3垂直碳纤维,4基质,5缝绗碳纤维。
具体实施方式
本实施例以生产高铁刹车盘为例,刹车盘内径348mm,外径640mm,厚度82mm。本实施例为本领域的普通技术人员可更好理解本发明,但本发明不局限于本实施例,在不脱离本发明的原理和宗旨的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由权利要求及其等同物限定。本实施例中虽然以高铁刹车盘为例进行说明,但本发明高温碳基刹车盘及其制作方法并不局限于高铁刹车盘,飞机、磁悬浮,船舰、汽车等交通工具刹车制动产品均可应用该高温碳基刹车盘,应用本发明制作方法获得。
本发明的高温碳基刹车盘,所述刹车盘包括碳纤维和基质4,所述刹车盘的两个侧面形成第一摩擦面1和第二摩擦面2,碳纤维沿刹车盘轴向分布,与摩擦面垂直,形成垂直碳纤维3,所述基质4为C/C-SiC-Si3N4复合材料基质。所述基质4为酚醛树酯、聚碳硅烷和聚氮硅烷按重量比100:(2-8):(1-3)配比,在高温下碳化得到的C/C-SiC-Si3N4复合材料基质。
高温碳基刹车盘加工方法包括以下步骤:
(1)制备胶膜;酚醛树酯、聚碳硅烷和聚氮硅烷按重量比100:(2-8):(1-3)的比例混合作为溶质,加入丙酮做溶剂进行搅拌,溶质和溶剂质量比25:75,制得胶膜,胶膜克重200-220g/㎡。使用的酚醛树酯树脂残存率为45%以上,并且游离基小于0.02。
(2)制备酚醛碳纤维预浸料;用胶膜与碳纤维原布制得预浸料,酚醛树脂与预浸料的重量比为33%-45%,碳纤维纱在纱架上在零度方向均匀棑纱,按幅宽1米进行单向铺放与胶膜粘合制成单向碳纤维预浸料。
(3)制备碳纤维管筒;以刹车盘内径大小348mm-2mm制成模具芯模,按照刹车盘的外径尺寸640mm+2mm将步骤(2)中的酚醛碳纤维预浸料高压卷缠在模具芯模上,并沿管筒环向用碳纤维进行绗缝制得碳纤维管筒。绗缝用人字纹绗缝,呈现±45°的交叉结构。缝绗碳纤维5与第一摩擦面1及第二摩擦面2平行或呈一定角度分布,缝绗碳纤维5也可成为摩擦面的组元。
(4)碳纤维管筒固化;将步骤(3)得到碳纤维管筒进行加热固化,固化温度160-220℃,时间120-180分钟,前90分钟缓慢升温至160-220℃,升温速度≤2℃/分钟,温度达160-220℃保温30-60分钟。
(5)分切;将固化的碳纤维管筒按照刹车盘坯体厚度82mm+2mm进行横截面分切得到刹车盘毛坯体。
(6)碳化;毛坯体放入碳化炉中进行碳化,碳化炉温度1200℃,无氧环境,将热处理炉抽真空至≤1KPa时升温;当升温至800-1000℃时,充Ar进行保护;继续升温至1200℃,保温1-2h进行高温热处理。
(7)精加工,将碳化的刹车盘半成品进行机械加工制得高温碳基刹车盘成品。
本发明制得的刹车盘摩擦系数0.34-0.51,可满足多种刹车制动产品的需求。
Claims (8)
1.一种高温碳基刹车盘,所述刹车盘包括碳纤维和基质,其特征是所述刹车盘的两个侧面形成第一摩擦面和第二摩擦面,所述碳纤维包括垂直碳纤维,垂直碳纤维沿刹车盘轴向分布,与摩擦面垂直,所述基质为C/C-SiC-Si3N4复合材料基质。
2.根据权利要求1所述的高温碳基刹车盘,其特征是所述基质为酚醛树酯、聚碳硅烷和聚氮硅烷按重量比100:(2-8):(1-3)配比,在高温下碳化得到的C/C-SiC-Si3N4复合材料基质。
3.根据权利要求1所述的高温碳基刹车盘,其特征是所述碳纤维还包括缝绗碳纤维,缝绗碳纤维与第一摩擦面及第二摩擦面平行或呈一定角度分布,缝绗碳纤维作为摩擦面的组元。
4.一种制备权利要求1-3任一项所述的高温碳基刹车盘的制作方法,其特征是包括以下步骤:
(1)制备胶膜,酚醛树酯、聚碳硅烷和聚氮硅烷按重量比100:(2-8):(1-3)的比例制得胶膜,胶膜克重200-220g/m2;
(2)制备酚醛碳纤维预浸料,用胶膜与碳纤维原布制得预浸料,酚醛树脂与预浸料的重量比33%-45%,碳纤维零度方向排布与胶膜粘合,制得单向酚醛碳纤维预浸料;
(3)制备碳纤维管筒,以刹车盘内径大小制成模具芯模,按照刹车盘的外径尺寸将步骤(2)中的酚醛碳纤维预浸料高压卷缠在模具芯模上,并沿管筒环向用碳纤维进行绗缝制得碳纤维管筒;
(4)碳纤维管筒固化,将步骤(3)得到碳纤维管筒进行加热固化,固化后脱模;
(5)分切,将固化的碳纤维管筒按照刹车盘坯体厚度要求进行横截面分切得到刹车盘毛坯体;
(6)碳化,毛坯体放入碳化炉中进行碳化,碳化炉温度1200℃,无氧环境;
(7)精加工,将碳化的刹车盘半成品进行机械加工制得高温碳基刹车盘成品。
5.根据权利要求4所述高温碳基刹车盘的制作方法,其特征是所述步骤(1)中酚醛树酯树脂残存率为45%以上,并且游离基小于0.02。
6.根据权利要求4所述高温碳基刹车盘的制作方法,其特征是所述步骤(3)中绗缝用人字纹绗缝,呈现±45°的交叉结构。
7.根据权利要求4所述高温碳基刹车盘的制作方法,其特征是所述步骤(4)中固化温度160-220℃,时间120-180分钟,前90分钟缓慢升温至160-220℃,升温速度≤2℃/分钟,温度达160-220℃保温30-60分钟。
8.根据权利要求4所述高温碳基刹车盘的制作方法,其特征是所述步骤(6)中将热处理炉抽真空至≤1KPa时升温;当升温至800-1000℃时,充Ar进行保护;继续升温至1200℃,保温1-2h进行高温热处理。
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