CN112157403A - Preparation method for preparing aluminum matrix composite brake disc - Google Patents
Preparation method for preparing aluminum matrix composite brake disc Download PDFInfo
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- CN112157403A CN112157403A CN202011011519.1A CN202011011519A CN112157403A CN 112157403 A CN112157403 A CN 112157403A CN 202011011519 A CN202011011519 A CN 202011011519A CN 112157403 A CN112157403 A CN 112157403A
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 205
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 205
- 239000002131 composite material Substances 0.000 title claims abstract description 182
- 239000011159 matrix material Substances 0.000 title claims abstract description 65
- 238000002360 preparation method Methods 0.000 title claims abstract description 17
- 239000002245 particle Substances 0.000 claims abstract description 76
- 238000003756 stirring Methods 0.000 claims abstract description 55
- 239000000919 ceramic Substances 0.000 claims abstract description 51
- 230000007704 transition Effects 0.000 claims abstract description 24
- 238000000034 method Methods 0.000 claims description 30
- 238000004519 manufacturing process Methods 0.000 claims description 21
- 239000000654 additive Substances 0.000 claims description 12
- 230000000996 additive effect Effects 0.000 claims description 12
- 238000002156 mixing Methods 0.000 claims description 9
- 238000001816 cooling Methods 0.000 claims description 8
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 4
- 238000004080 punching Methods 0.000 claims description 3
- 210000001787 dendrite Anatomy 0.000 claims description 2
- 238000009792 diffusion process Methods 0.000 abstract description 3
- 238000005266 casting Methods 0.000 description 22
- 230000003014 reinforcing effect Effects 0.000 description 18
- 239000000463 material Substances 0.000 description 13
- 230000007547 defect Effects 0.000 description 11
- -1 aluminum-silicon-copper Chemical compound 0.000 description 8
- 229910045601 alloy Inorganic materials 0.000 description 6
- 239000000956 alloy Substances 0.000 description 6
- 239000012535 impurity Substances 0.000 description 6
- 239000007788 liquid Substances 0.000 description 6
- 239000003607 modifier Substances 0.000 description 6
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 229910000881 Cu alloy Inorganic materials 0.000 description 4
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 4
- 239000004411 aluminium Substances 0.000 description 4
- 239000013078 crystal Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 238000005204 segregation Methods 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
- 229910000676 Si alloy Inorganic materials 0.000 description 3
- 229910001278 Sr alloy Inorganic materials 0.000 description 3
- YNDGDLJDSBUSEI-UHFFFAOYSA-N aluminum strontium Chemical compound [Al].[Sr] YNDGDLJDSBUSEI-UHFFFAOYSA-N 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 238000007670 refining Methods 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 238000007872 degassing Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000004134 energy conservation Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000011112 process operation Methods 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 229910000789 Aluminium-silicon alloy Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 229910000861 Mg alloy Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- WPPDFTBPZNZZRP-UHFFFAOYSA-N aluminum copper Chemical compound [Al].[Cu] WPPDFTBPZNZZRP-UHFFFAOYSA-N 0.000 description 1
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 239000006023 eutectic alloy Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000009714 stir casting Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Braking Arrangements (AREA)
Abstract
The invention provides a preparation method for preparing an aluminum matrix composite brake disc, which comprises the following steps: blank forming step S1: forming a brake disc blank by using an aluminum ingot; aluminum-based composite plate forming step S2: forming an aluminum-based composite plate by using an aluminum-based composite material; stacking step S3: stacking the aluminum-based composite plate above the brake disc blank to form a composite structure in which the aluminum-based composite plate and the brake disc blank are stacked; friction stir processing step S6: and (3) carrying out friction stir processing on the surface of the composite structure to generate a transition layer between the aluminum-based composite plate and the brake disc blank, so that the aluminum-based composite plate and the brake disc blank are combined together. The invention can improve the ceramic particle fraction on the surface of the aluminum-based composite material, increase the wear resistance, and the brake disc blank is not added with ceramic particles, thereby improving the mechanical properties such as elongation and the like, reducing the failure risk, increasing the thermal diffusion coefficient of the brake disc, transferring the heat generated by a friction layer and reducing the temperature rise.
Description
Technical Field
The invention relates to the field of brake disc preparation, in particular to a preparation method for preparing an aluminum matrix composite brake disc.
Background
With the increasing environmental protection pressure, energy conservation, emission reduction and environmental pollution reduction become the basic national policies of the present day. The weight of the rail transit vehicle is reduced, and energy consumption and emission caused by frequent starting and braking are reduced, so that the method is one of the most effective methods for realizing energy conservation and emission reduction. One of the main approaches to reduce the weight of rail transit vehicles at present is to use a brake disc made of a novel light material to replace a traditional brake disc made of steel or iron material, so as to reduce the weight of the material of unsprung parts of the running vehicle and maintain an ideal unsprung weight ratio of the sprung part to the unsprung part. The existing light material brake disc mainly comprises a carbon/carbon fiber composite material, a ceramic composite material, an aluminum matrix composite material brake disc and the like.
The brake disc made of the existing aluminum-based composite material is mainly a brake disc made of a ceramic particle reinforced aluminum-based composite material, such as a brake disc made of a SiC particle reinforced aluminum-based composite material, and the whole brake disc is made of the same material. The alloy is mainly prepared by a vacuum stirring casting method. The aluminum matrix composite brake disc prepared by the method has the following technical problems:
firstly, when the aluminum matrix composite is prepared by a vacuum stirring casting method, although the wear resistance of the aluminum matrix composite brake disc can be improved by increasing the adding amount of the ceramic particles, the toughness can be reduced to influence the comprehensive mechanical property of the aluminum matrix composite brake disc, and the forming property of the aluminum matrix composite is influenced to cause the defects of insufficient pouring or air hole slag inclusion. In view of the above reasons, the ceramic particle addition amount of the ceramic particle reinforced aluminum matrix composite brake disc prepared by the vacuum stirring casting method in the prior art is about 20%, and the requirement of wear resistance is difficult to meet.
Secondly, the vacuum stirring casting equipment has higher requirements on the process control level, and the prepared ceramic particle reinforced aluminum matrix composite brake disc is easy to generate defects such as air holes, slag inclusion, ceramic particle segregation and the like;
third, a large investment is required due to the use of an expensive vacuum agitation manufacturing apparatus.
Disclosure of Invention
The main object of the present invention is to provide a method for manufacturing a brake disc made of an aluminum matrix composite, so as to solve the above problems in the prior art.
In order to achieve the above object, according to one aspect of the present invention, there is provided a manufacturing method for manufacturing an aluminum matrix composite brake disc, the manufacturing method including the steps of:
blank forming step S1: forming a brake disc blank by using an aluminum ingot;
aluminum-based composite plate forming step S2: forming an aluminum-based composite plate by using an aluminum-based composite material;
stacking step S3: stacking the aluminum-based composite plate above the brake disc blank to form a composite structure in which the aluminum-based composite plate and the brake disc blank are stacked;
friction stir processing step S6: and (3) carrying out friction stir processing on the surface of the composite structure, generating a transition layer between the aluminum-based composite plate and the brake disc blank, and combining the aluminum-based composite plate and the brake disc blank together.
Further, in the friction stir processing step S6, the original dendrites in the brake disc blank and the aluminum-based composite plate are broken up to obtain refined grains of the brake disc blank and the aluminum-based composite plate.
Further, in the aluminum-based composite plate forming step S2, an aluminum-based composite plate having a plurality of through holes is prepared by a direct punching method.
Further, in the aluminum-based composite plate forming step S2, a plurality of through holes are formed in a matrix shape arrangement on the aluminum-based composite plate.
Further, the aluminum-based composite plate forming step S2 includes:
aluminum-based circular plate forming step S21: a step of forming a circular aluminum-based plate by using an aluminum-based composite material;
via forming step S22: a plurality of through holes are arranged on the aluminum-based circular plate.
Further, an additive adding step S4 is included after the stacking step S3: a particulate additive is added to the plurality of through holes.
Further, an aluminum plate covering step S5 is also included after the additive adding step S4: and covering a layer of aluminum plate for covering the granular additive above the aluminum-based composite plate.
Further, in the additive adding step S4, the particulate additive is ceramic particles.
Further, the ceramic particles are any one or more of SiC, TiN, and BN.
Further, the friction stir processing step S6 includes a mixing step S61 and a cooling step S62, and in the mixing step S61, the portions of the brake disc blank and the aluminum-based composite plate that are in contact with each other are mixed together; in the cooling step S62, a brake disk having a transition layer formed of mixed portions is formed.
By applying the technical scheme of the invention, the beneficial effects are as follows:
1. the preparation method can improve the ceramic particle fraction on the surface of the aluminum matrix composite material, increase the wear resistance, and compared with vacuum stirring casting, the brake disc matrix is free from ceramic particles, so that the comprehensive mechanical properties such as elongation and the like of the matrix can be effectively improved, the failure risk is reduced, the thermal diffusion coefficient of the brake disc is increased, the heat generated by a friction layer can be transferred, and the temperature rise of the brake disc is reduced.
2. In the prior art, the aluminum matrix composite brake disc prepared by vacuum stirring casting integrally adopts the same ceramic particle reinforced aluminum matrix composite, and during the preparation process, the ceramic particles are easy to generate segregation defects in the aluminum matrix composite, so that the mechanical property of the brake disc is poor; compared with the prior art, the ceramic particles of the aluminum matrix composite brake disc prepared by the preparation method provided by the invention are more uniformly distributed, and the prepared aluminum matrix composite brake disc has good wear resistance and toughness.
3. In the prior art, in the aluminum matrix composite brake disc prepared by vacuum stirring casting, the adding amount of the ceramic particles is limited, because the adding of the ceramic particles can improve the wear resistance but can reduce the toughness. Therefore, the addition amount of the ceramic particles in the brake disc made of the aluminum matrix composite material prepared by the prior art is about 20 percent, so that the brake disc is ensured to have wear resistance and not too low in toughness. Compared with the prior art, the aluminum matrix composite brake disc prepared by the invention has more uniform internal structure, when the addition of the ceramic particles exceeds 20%, the added ceramic particles exist near the transition layer, and the brake disc as a whole still has good toughness, can improve the wear resistance and has better overall mechanical property.
4. Compared with the defects that the existing vacuum stirring casting method is easy to generate air holes, impurities and the like, the aluminum matrix composite brake disc prepared by the preparation method provided by the invention has more uniform tissue, fewer defects and no defects of air holes, impurities and the like, so that the aluminum matrix composite brake disc has better mechanical properties compared with the aluminum matrix composite brake disc in the prior art.
5. Compared with the prior art, the vacuum stirring casting equipment with high price is not adopted, so that the production cost is greatly reduced.
6. In the prior art, the vacuum stirring casting process needs to be carried out at high temperature, and operators may have operation safety risk during operation, while the stirring friction processing process is carried out at non-high temperature, so that the process is simplified and the safety of process operation is ensured.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 shows a schematic diagram of a process route of the present invention;
FIG. 2 shows a schematic view of an aluminum-based composite brake disc structure made using the present invention;
FIG. 3 shows a schematic representation of a composite layer, transition layer and substrate layer structure prepared using the present invention;
FIG. 4 shows a schematic representation of a cross-sectional view of a composite layer, a transition layer, and a substrate layer of the present invention;
FIG. 5 shows a metallographic structure of an aluminum-based composite brake disc without friction stir processing;
fig. 6 shows a metallographic structure diagram of an aluminum-based composite material brake disc processed by friction stir processing.
Detailed Description
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
The present invention is described in further detail below with reference to specific examples, which are not to be construed as limiting the scope of the invention as claimed.
Referring to fig. 1, the method for manufacturing the brake disc made of the aluminum matrix composite according to the present invention is implemented according to the following steps:
s1: and forming a brake disc blank by adopting an aluminum-silicon alloy or an aluminum-silicon-copper alloy as a matrix alloy through a casting forming process. Firstly, aluminum-silicon alloy or aluminum-silicon-copper alloy or aluminum-silicon (copper) alloy containing a small amount of ceramic particles is used as matrix alloy to form an aluminum ingot, and an aluminum-strontium alloy modifier and an aluminum-titanium-boron refiner are weighed according to the weight of the aluminum ingot. And then, putting the aluminum ingot, the aluminum-strontium alloy modifier and the aluminum-titanium-boron refiner into an oven for baking to remove moisture. And heating the dried aluminum ingot to 700-800 ℃, adding an aluminum strontium alloy modifier, a refining agent and an aluminum titanium boron refiner into the aluminum ingot when the aluminum ingot is completely melted, and introducing argon into the melted aluminum liquid for degassing for 30-50 minutes. Controlling the temperature of the aluminum liquid at 700-720 ℃, and pouring the brake disc blank by using a special metal mold for the brake disc through low-pressure pouring, wherein the pouring process comprises liquid rising, mold filling, crusting, pressure maintaining and pressure relief. And finally, opening the die and taking out the aluminum alloy brake disc blank casting. And (4) carrying out primary processing on the brake disc blank according to the profile size of the disc surface of the brake disc to obtain the aluminum alloy brake disc blank.
The main part of the brake disc is a brake disc blank, which has higher requirement on strength. The brake disc blank prepared by the embodiment has the advantages that the refiner, the refining agent and the modifier are added into the aluminum liquid, so that the formed aluminum ingot is more uniform in structure and has enough strength, and the failure risks such as deformation, cracks and the like in the use process can be reduced. The properties of the brake disc blank produced in this example were as follows: rm is more than or equal to 230MPa, the elongation is more than or equal to 2, and the hardness is more than or equal to 90 HB.
S2: the step of forming the aluminum-based composite plate using the aluminum-based composite material includes an aluminum-based circular plate forming step S21 and a through-hole forming step S22.
In the aluminum base circular plate forming step S21, first, the mass of the modifier and the refiner is weighed in accordance with the weight ratio of the aluminum material. Sieving the reinforced particles to remove agglomerated particle groups and other impurities, and placing the reinforced particles into an oven for roasting pretreatment at the temperature of 200-500 ℃ to remove surface impurities and adsorb moisture. In the present embodiment, the reinforcing particles mean ceramic particles such as SiC, TiN, or BN. And putting the aluminum ingot, the alterant and the refiner into an oven for baking to remove moisture. Heating the aluminum ingot to 650-800 ℃, adding an alloying material, a modifier and a refining agent when the aluminum ingot is completely melted, and introducing argon into the aluminum liquid for degassing treatment for 30-50 minutes. And controlling the temperature of the aluminum liquid at 600-800 ℃, and rolling into a plate.
In the through hole forming step S22, the aluminum-based composite board is punched into a circular aluminum-based board with the outer diameter of 600-800 mm and the inner diameter of 250-350 mm by punching, a plurality of through holes with the diameter of 5-7 mm are distributed on the circular aluminum-based board, the whole disc is full of the through holes, and the through holes are distributed on the aluminum-based composite board in a matrix shape. The thickness of the aluminum-based composite plate prepared in the embodiment is 3-7 mm. The properties of the aluminum-based composite panel are as follows: rm is more than or equal to 200MPa, elongation is more than or equal to 0.5, and hardness is more than or equal to 80 HB.
S3: and stacking the aluminum-based composite plate above the brake disc blank to form a stacked composite structure. Firstly, fixing a brake disc blank on a stirring and rubbing workbench, and stacking an aluminum-based composite board above the brake disc blank to form a composite structure. In the composite structure, the brake disc blank is arranged below the aluminum-based composite plate, so that the bottom of the through hole of the aluminum-based composite plate is sealed by the brake disc blank, and the matrix-shaped through hole with the sealed bottom is formed.
S4: weighing SiC particles as reinforcing particles, and baking at high temperature in advance to remove the surfaceImpurities. During the high-temperature baking process, a layer of SiO is formed on the surface of the SiC particles2And the contact wettability of the SiC particles and the brake disc blank can be improved by the oxide film. And adding the weighed SiC particles into the matrix through holes on the aluminum-based composite board, and filling the through holes with the reinforcing particles.
S5: after the through holes are filled with the reinforcing particles, a layer of aluminum plate used for covering the reinforcing particles is covered above the aluminum-based composite plate. The thickness of the aluminum plate is 0.5-1 mm. On one hand, the aluminum plate can cover SiC particles, so that the SiC particles are prevented from splashing in the subsequent friction stir processing process; on the other hand, the aluminum base composite plate is metallurgically combined with the aluminum base composite plate in the subsequent stirring friction processing process, so that the toughness of the aluminum base composite plate can be improved; meanwhile, direct contact between the stirring head and the SiC particles can be reduced, and abrasion of a stirring pin at the bottom of the stirring head is reduced.
S6: and (3) carrying out friction stir processing on the surface of the composite structure of the brake disc blank and the aluminum-based composite plate, wherein the surface refers to the upper surface of the aluminum-based composite plate, and when an aluminum plate covering the reinforcing particles is arranged, the surface is the upper surface covering the aluminum plate, but not the lower surface contacting with the brake disc blank. The friction stir processing specifically includes two steps, a mixing step S61 and a cooling step S62 after the mixing step.
The mixing step S61 is a step of mixing the portions of the brake disc blank and the aluminum-based composite plate that are in contact with each other, and the cooling step S62 is a step of cooling the portions of the brake disc blank and the aluminum-based composite plate that are in contact with each other after mixing, and during the cooling step, a transition layer is formed between the brake disc blank and the aluminum-based composite plate to obtain an aluminum-based composite brake disc having a transition layer, the transition layer being formed of the mixed portions.
In the process of the friction stir processing, the stirring speed of the friction stir processing is 600-. The friction stir processing tool comprises a stirring head, the stirring head is utilized to rotate at a high speed to heat the surface of the aluminum-based composite plate to a plastic state, and SiC particles in the small holes are extruded and brought into the aluminum-based composite plate. Meanwhile, a transition layer is generated between the aluminum-based composite plate and the brake disc blank in the friction stir processing process, so that the brake disc blank and the aluminum-based composite plate can be combined together. This bonding is a metallurgical bonding. In the stirring friction processing process, original dendritic crystals near the contact surface of the brake disc blank and the aluminum-based composite plate are broken, and a structure with smaller and more uniform grain sizes is obtained. Therefore, the bonding force between the brake disc blank and the aluminum-based composite plate is strengthened.
S7: and (6) machining and removing blank seams on the surface of the aluminum matrix composite brake disc prepared in the step (6) to finish machining of the reference surface of the aluminum matrix composite brake disc.
Compared with the integral brake disc in the prior art, the brake disc made of the aluminum-based composite material and prepared by the preparation method disclosed by the invention is different in that the brake disc made of the aluminum-based composite material and prepared by the preparation method disclosed by the invention is made of different materials. The integral brake disc refers to an aluminum matrix composite brake disc of which the whole brake disc is made of the same aluminum matrix composite. In the prior art, the integral aluminum matrix composite brake disc is mainly prepared by a vacuum stirring casting method, and the whole body of the brake disc is made of the same ceramic particle reinforced aluminum matrix composite. Because the hardness of the ceramic particles is higher, the addition of the ceramic particles can enhance the wear resistance of the brake disc, but simultaneously reduce the toughness of the brake disc, thereby reducing the overall mechanical performance of the brake disc. Therefore, in the prior art, the addition amount of the ceramic particles is usually about 20%, and if the addition amount exceeds 20%, the aluminum matrix composite brake disc containing the ceramic particles has poor comprehensive mechanical properties. In addition, vacuum stirring casting equipment is expensive, so that the cost for preparing the aluminum matrix composite brake disc through a stirring casting process is high.
The aluminum-based composite material brake disc prepared by the preparation method is prepared by stirring and rubbing two brake disc blanks made of different materials and an aluminum-based composite plate. Wherein, the brake disc blank is aluminum-silicon alloy or aluminum-silicon-copper alloy and mainly plays a bearing role. The aluminium-silicon alloy or the aluminium-silicon-copper alloy may be a hypoeutectic alloy or a eutectic alloy or a hypereutectic alloy. In the embodiment, a small amount of ceramic particles are added into the brake disc blank, so that the mechanical property, the impact resistance and the high-temperature resistance of the brake disc blank can be improved.
The aluminum-based composite plate is an aluminum-based composite material containing ceramic particles, and has good frictional wear performance, so that the aluminum-based composite plate has the function of providing frictional braking force. The aluminum-based composite material is formed by adding ceramic particles such as SIC, TiN or BN into aluminum copper or aluminum silicon or aluminum magnesium alloy. Preferably, , any one or more of zirconium, lanthanum and cerium are added into the aluminum-based composite material to prepare the aluminum-based composite plate, so that the performance of the aluminum-based composite plate can be improved. Add above-mentioned ceramic particle in the through-hole on aluminium base composite panel, cover one deck aluminum plate above adding aluminium base composite panel that has ceramic particle, can make the ceramic particle in the through-hole get into in the aluminium base composite material of circumference through friction stir processing, for prior art's vacuum stirring casting, the distribution of ceramic particle in aluminium base composite material is more even. This is because, during vacuum stir casting, ceramic particles are likely to agglomerate to form defects such as segregation. In the embodiment, in the aluminum-based composite brake disc prepared by the invention, the ceramic particle content of the aluminum-based composite plate is between 15% and 30%. Preferably, the ceramic particle content of the aluminum matrix composite material is between 20% and 30%. The size of the ceramic particles is 10-40 μm, and the normal distribution value is 10-30 μm. The thickness of the aluminum-based composite plate is 3-10 mm.
In the brake disc made of the aluminum-based composite material, the contact part of the aluminum-based composite plate and the brake disc blank forms a transition layer. Macroscopically, the transition layer consists of an aluminum-based composite plate and a brake disc blank. In the cross-sectional interface diagrams of the brake disc made of the aluminum-based composite material, as shown in fig. 3 and 4, the transition layer comprises a strengthening structure, so that the bonding force between the aluminum-based composite plate and the brake disc blank can be increased. The reinforcing structure refers to a boundary surface where the aluminum-based composite material and the brake disc blank enter each other after friction stir processing, and is a boundary line of the two materials in fig. 3 and 4. FIG. 3 is a schematic diagram of the structure of the composite layer, transition layer and substrate layer prepared by the present invention; FIG. 4 shows a schematic representation of a cross-sectional view of a composite layer, a transition layer, and a substrate layer of the present invention. Such a reinforcing structure is a non-planar structure. Such non-planar structures are irregularly shaped structures. Preferably, such irregularly shaped structures are saw tooth and/or inverted trapezoidal and/or regular trapezoidal structures. The reinforced structure realizes the component transition between the reinforced blank of the brake disc and the aluminum-based composite plate. The reinforcing structure comprises a first reinforcing part and a second reinforcing part. The first reinforcing portion is a structure directed deep into the aluminum-based composite panel, and exhibits a convex-like shape as shown in fig. 3. The material composition of the brake disc blank and the SiC particles increase in a gradient from the brake disc blank to the first reinforcing portion. From the first reinforcing part to the aluminum-based composite board, the material components and SiC particles of the aluminum-based composite board increase in a gradient manner. The second reinforcing portion is a structure that points deep into the brake disc blank, as shown in fig. 3, assuming a concave-like shape. From the aluminum-based composite board to the second reinforcing structure, the components of the aluminum-based composite material and SiC particles are reduced in a gradient manner. From the second reinforced part to the brake disc blank, the material composition of the brake disc blank increases in a gradient manner, and the SiC particles decrease in a gradient manner. The distance between the apex of the first reinforcing structure and the apex of the second reinforcing structure is the thickness of the transition layer. The thickness of the transition layer is 1-5 mm. The elongation of the transition layer is A more than or equal to 1 percent. From the microstructure, the size of the microscopic crystal of the transition layer is smaller than the size of the microscopic crystal particles of the brake disc blank and the aluminum-based composite plate. The length of the microscopic crystal particles of the transition layer is less than or equal to 10 mu m.
As can be seen from comparing fig. 5 and fig. 6, the aluminum matrix composite brake disc without friction stir processing has larger metallographic structure particles, as shown in fig. 5; the aluminum matrix composite brake disc processed by friction stir processing has smaller metallographic structure particles, as shown in fig. 6.
From the above description, it can be seen that the above-described embodiments of the present invention achieve the following technical effects:
1. the preparation method can improve the ceramic particle fraction on the surface of the aluminum matrix composite material, increase the wear resistance, and compared with vacuum stirring casting, the brake disc matrix is free from ceramic particles, so that the comprehensive mechanical properties such as elongation and the like of the matrix can be effectively improved, the failure risk is reduced, the thermal diffusion coefficient of the brake disc is increased, the heat generated by a friction layer can be transferred, and the temperature rise of the brake disc is reduced.
2. In the prior art, the aluminum matrix composite brake disc prepared by vacuum stirring casting integrally adopts the same ceramic particle reinforced aluminum matrix composite, and during the preparation process, the ceramic particles are easy to generate segregation defects in the aluminum matrix composite, so that the mechanical property of the brake disc is poor; compared with the prior art, the ceramic particles of the aluminum matrix composite brake disc prepared by the preparation method provided by the invention are more uniformly distributed, and the prepared aluminum matrix composite brake disc has good wear resistance and toughness.
3. In the prior art, in the aluminum matrix composite brake disc prepared by vacuum stirring casting, the adding amount of the ceramic particles is limited, because the adding of the ceramic particles can improve the wear resistance but can reduce the toughness. Therefore, the addition amount of the ceramic particles in the brake disc made of the aluminum matrix composite material prepared by the prior art is about 20 percent, so that the brake disc is ensured to have wear resistance and not too low in toughness. Compared with the prior art, the aluminum matrix composite brake disc prepared by the invention has more uniform internal structure, when the addition of the ceramic particles exceeds 20%, the added ceramic particles exist near the transition layer, and the brake disc as a whole still has good toughness, can improve the wear resistance and has better overall mechanical property.
4. Compared with the defects that the existing vacuum stirring casting method is easy to generate air holes, impurities and the like, the aluminum matrix composite brake disc prepared by the preparation method provided by the invention has more uniform tissue, fewer defects and no defects of air holes, impurities and the like, so that the aluminum matrix composite brake disc has better mechanical properties compared with the aluminum matrix composite brake disc in the prior art.
5. Compared with the prior art, the vacuum stirring casting equipment with high price is not adopted, so that the production cost is greatly reduced.
6. In the prior art, the vacuum stirring casting process needs to be carried out at high temperature, and operators may have operation safety risk during operation, while the stirring friction processing process is carried out at non-high temperature, so that the process is simplified and the safety of process operation is ensured.
Claims (10)
1. A preparation method for preparing an aluminum matrix composite brake disc is characterized by comprising the following steps:
blank forming step S1: forming a brake disc blank by using an aluminum ingot;
aluminum-based composite plate forming step S2: forming an aluminum-based composite plate by using an aluminum-based composite material;
stacking step S3: stacking the aluminum-based composite plate above the brake disc blank to form a composite structure in which the aluminum-based composite plate and the brake disc blank are stacked;
friction stir processing step S6: and (3) carrying out friction stir processing on the surface of the composite structure, generating a transition layer between the aluminum-based composite plate and the brake disc blank, and combining the aluminum-based composite plate and the brake disc blank together.
2. The manufacturing method for manufacturing the brake disc made of the aluminum-based composite material according to claim 1, wherein in the friction stir processing step S6, the original dendrites in the brake disc blank and the aluminum-based composite plate are broken up to obtain refined grains of the brake disc blank and the aluminum-based composite plate.
3. The manufacturing method for manufacturing an aluminum-based composite brake disc according to claim 1, wherein, in the aluminum-based composite plate forming step S2, the aluminum-based composite plate having a plurality of through holes is manufactured by a direct punching method.
4. The production method for the aluminum-based composite material brake disc according to claim 1, wherein in the aluminum-based composite plate forming step S2, a plurality of through holes are formed in a matrix shape arrangement on the aluminum-based composite plate.
5. The manufacturing method for manufacturing an aluminum-based composite brake disc according to claim 3, wherein said aluminum-based composite plate forming step S2 includes:
aluminum-based circular plate forming step S21: a step of forming a circular aluminum-based plate by using an aluminum-based composite material;
via forming step S22: the aluminum-based circular plate is provided with the through hole.
6. The method for manufacturing an aluminum matrix composite brake disc according to claim 5, further comprising an additive addition step S4 after said stacking step S3: adding a particulate additive to the through-holes.
7. The method for manufacturing an aluminum matrix composite brake disc according to claim 6, further comprising an aluminum plate covering step S5 after the additive adding step S4: and covering a layer of aluminum plate for covering the granular additive above the aluminum-based composite plate.
8. The manufacturing method for manufacturing an aluminum matrix composite brake disc according to claim 6, wherein in the additive adding step S4, the particulate additive is ceramic particles.
9. The production method for producing an aluminum matrix composite brake disc according to claim 8, wherein the ceramic particles are any one or more of SiC, TiN and BN.
10. The method for manufacturing a brake disc made of an aluminum-based composite material according to any one of claims 1 to 9, wherein the friction stir processing step S6 includes a mixing step S61 and a cooling step S62, and in the mixing step S61, the brake disc blank and the aluminum-based composite plate are mixed together at the portions where they contact each other; in the cooling step S62, a brake disk having a transition layer formed by the mixed portion is formed.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011011519.1A CN112157403A (en) | 2020-09-23 | 2020-09-23 | Preparation method for preparing aluminum matrix composite brake disc |
| MX2023003366A MX2023003366A (en) | 2020-09-23 | 2021-09-20 | Composite material brake rotor, preparation method therefor, and friction stir tool. |
| PCT/CN2021/119478 WO2022063099A1 (en) | 2020-09-23 | 2021-09-20 | Composite material brake rotor, preparation method therefor, and friction stir tool |
| US18/028,003 US20230349435A1 (en) | 2020-09-23 | 2021-09-20 | Composite brake disc, preparation method thereof and friction stir tool |
| CN202180065279.XA CN116348234A (en) | 2020-09-23 | 2021-09-20 | Composite brake disc, preparation method thereof and friction stir tool |
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| CN202011011519.1A CN112157403A (en) | 2020-09-23 | 2020-09-23 | Preparation method for preparing aluminum matrix composite brake disc |
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