CN115190916B - 具有抗磨损性和防腐蚀性的制动盘及其生产方法 - Google Patents
具有抗磨损性和防腐蚀性的制动盘及其生产方法 Download PDFInfo
- Publication number
- CN115190916B CN115190916B CN202080097715.7A CN202080097715A CN115190916B CN 115190916 B CN115190916 B CN 115190916B CN 202080097715 A CN202080097715 A CN 202080097715A CN 115190916 B CN115190916 B CN 115190916B
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- China
- Prior art keywords
- brake disc
- metal body
- diffusion layer
- coating
- friction surface
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 238000005260 corrosion Methods 0.000 title abstract description 36
- 230000007797 corrosion Effects 0.000 title abstract description 35
- 238000009792 diffusion process Methods 0.000 claims abstract description 63
- 229910052751 metal Inorganic materials 0.000 claims abstract description 51
- 239000002184 metal Substances 0.000 claims abstract description 51
- 238000000576 coating method Methods 0.000 claims abstract description 39
- 229910000789 Aluminium-silicon alloy Inorganic materials 0.000 claims abstract description 33
- 239000011248 coating agent Substances 0.000 claims abstract description 32
- 229910001060 Gray iron Inorganic materials 0.000 claims abstract description 11
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 9
- 239000010959 steel Substances 0.000 claims abstract description 9
- 239000010410 layer Substances 0.000 claims description 88
- 229910045601 alloy Inorganic materials 0.000 claims description 29
- 239000000956 alloy Substances 0.000 claims description 29
- 238000009423 ventilation Methods 0.000 claims description 26
- 239000000463 material Substances 0.000 claims description 23
- 238000000034 method Methods 0.000 claims description 23
- 238000010438 heat treatment Methods 0.000 claims description 19
- 230000001681 protective effect Effects 0.000 claims description 19
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 15
- 239000012298 atmosphere Substances 0.000 claims description 14
- 238000005507 spraying Methods 0.000 claims description 14
- 229910052710 silicon Inorganic materials 0.000 claims description 13
- 239000010703 silicon Substances 0.000 claims description 13
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 11
- 229910052782 aluminium Inorganic materials 0.000 claims description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 11
- 238000003754 machining Methods 0.000 claims description 9
- 229910052742 iron Inorganic materials 0.000 claims description 8
- 238000004040 coloring Methods 0.000 claims description 7
- 239000000126 substance Substances 0.000 claims description 7
- 239000000843 powder Substances 0.000 claims description 6
- 239000002344 surface layer Substances 0.000 claims description 6
- 238000010285 flame spraying Methods 0.000 claims description 4
- 239000003973 paint Substances 0.000 claims description 4
- 239000004411 aluminium Substances 0.000 claims description 3
- 230000003247 decreasing effect Effects 0.000 claims description 2
- 238000005470 impregnation Methods 0.000 claims description 2
- 239000007788 liquid Substances 0.000 claims description 2
- 238000003466 welding Methods 0.000 claims 1
- 238000005516 engineering process Methods 0.000 abstract description 3
- 230000003993 interaction Effects 0.000 abstract description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 16
- 230000015572 biosynthetic process Effects 0.000 description 10
- 238000005299 abrasion Methods 0.000 description 8
- 230000000694 effects Effects 0.000 description 7
- -1 iron-aluminum compound Chemical class 0.000 description 7
- 230000008569 process Effects 0.000 description 5
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- KCZFLPPCFOHPNI-UHFFFAOYSA-N alumane;iron Chemical class [AlH3].[Fe] KCZFLPPCFOHPNI-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000005422 blasting Methods 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- 239000010431 corundum Substances 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 238000013016 damping Methods 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 230000001627 detrimental effect Effects 0.000 description 2
- 150000001247 metal acetylides Chemical class 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 239000012299 nitrogen atmosphere Substances 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000007788 roughening Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- 229910010413 TiO 2 Inorganic materials 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- GVEHJMMRQRRJPM-UHFFFAOYSA-N chromium(2+);methanidylidynechromium Chemical compound [Cr+2].[Cr]#[C-].[Cr]#[C-] GVEHJMMRQRRJPM-UHFFFAOYSA-N 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
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- 239000000428 dust Substances 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
- 239000012266 salt solution Substances 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 238000007592 spray painting technique Methods 0.000 description 1
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- 229910003470 tongbaite Inorganic materials 0.000 description 1
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/10—Drums for externally- or internally-engaging brakes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
- F16D65/127—Discs; Drums for disc brakes characterised by properties of the disc surface; Discs lined with friction material
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- C—CHEMISTRY; METALLURGY
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- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
- C23C10/34—Embedding in a powder mixture, i.e. pack cementation
- C23C10/36—Embedding in a powder mixture, i.e. pack cementation only one element being diffused
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
- C23C10/34—Embedding in a powder mixture, i.e. pack cementation
- C23C10/36—Embedding in a powder mixture, i.e. pack cementation only one element being diffused
- C23C10/48—Aluminising
- C23C10/50—Aluminising of ferrous surfaces
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- C23C2/12—Aluminium or alloys based thereon
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/028—Including graded layers in composition or in physical properties, e.g. density, porosity, grain size
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
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- C23C4/08—Metallic material containing only metal elements
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
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- F16D2065/13—Parts or details of discs or drums
- F16D2065/1304—Structure
- F16D2065/132—Structure layered
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0004—Materials; Production methods therefor metallic
- F16D2200/0026—Non-ferro
- F16D2200/003—Light metals, e.g. aluminium
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2250/00—Manufacturing; Assembly
- F16D2250/0038—Surface treatment
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Abstract
本发明涉及车辆技术和工业设备技术的领域,并且涉及一种具有抗磨损性和防腐蚀性的制动盘及其生产方法。已知方案的缺点在于,防腐蚀和抗磨损涂层涂覆在制动盘的摩擦表面上,并且在首次制动操作中,该涂层很快会被摩擦掉。本发明通过提供一种耐用的制动盘,其防腐蚀性和抗磨损性得到了提高,而解决了上述问题。根据本发明,使至少摩擦表面(2)的区域具有AlSi基扩散层(3),该AlSi基扩散层的层厚度为0.1mm至0.6mm并且该AlSi基扩散层在与金属主体(1)的钢或灰铸铁的相互作用过程中形成,因此,制动盘的抗磨损性和防腐蚀性得到显著提高。根据本发明的制动盘可以例如用在车辆中、用作工业制动器的制动***、或用在风力涡轮机中。
Description
技术领域
本发明涉及车辆技术和工业设备技术领域,并且涉及一种具有抗磨损性和防腐蚀性的制动盘及其生产方法。根据本发明生产的制动盘可以例如用在车辆中、用作工业制动器的制动***或用在风力涡轮机中。
背景技术
车辆和工业应用中的常规制动盘设计为由金属或陶瓷材料制成的一体式制动盘或设计为由一种或多种金属或陶瓷材料制成的复合制动盘或多部件式制动盘。
制动盘具有多个功能区。例如,机动车辆中的制动盘被拧在前车轴和后车轴上,并且因此具有平面接触表面,该平面接触表面首先与轮辋接触,其次与车轮轴承接触。整个制动盘借助于车轮螺栓通过接触表面连接。
此外,制动盘具有带摩擦表面的区域,经由该区域,结合摩擦制动衬面制动盘实现了制动作用。
为了更好地驱散产生的热量,制动盘可以采用例如内部通风式盘式制动器的形式。为此,制动盘在制动盘盖内侧具有相应的吸入空气的通风管道,空气流经制动盘以散热,从而确保对制动盘的冷却。
对于现有技术中的制动盘,在摩擦表面区域中具有短期防腐蚀性,或在通风管道的区域中具有长期防腐蚀性。短期防腐蚀性仅能在短期内保护制动盘免受腐蚀。
现有技术公开了保护制动盘免受腐蚀和磨损的各种方案。
DE 20 2018 107 169 U1公开了一种涂层,尤其是用于制动盘、制动鼓和离合器片的涂层,所述涂层具有第一层和第二层,所述第一层包括含有小于20wt%的碳化钨或其他碳化物的金属基材料;所述第二层涂覆于所述第一层上并且包括含有碳化钨的材料,该材料含有20wt%-94wt%的碳化钨,其中所述第一层和所述第二层均为热喷涂层。
DE 20 2018 102 703 U1公开了一种用于车辆的制动体,所述制动体具有主体,所述主体具有通过粗糙化形成为摩擦表面的表面和在粗糙化之后通过热喷涂方法涂覆于摩擦表面上的涂层。
此外,从DE 20 2018 102 704 U1还已知一种用于车辆的制动体,所述制动体具有主体,所述主体具有:呈摩擦表面形式的第一表面;与所述摩擦表面相邻并且呈主表面形式的第二表面;以及涂覆于所述主表面的主表面涂层。
另外,从DE 102 03 507 A1已知一种用于车辆的制动盘,所述制动盘包括由金属材料,尤其是灰铸铁制成的主体,所述主体具有至少一个摩擦表面,所述摩擦表面具有由硬质材料制成的涂层,其中,涂层下面的主体在轴向平行于制动盘的轴线的方向上具有已移除的材料厚度,其中,所述主体在轴向平行于制动盘的轴线的方向上被移除的材料厚度近似为涂层的层厚度,或者被移除的材料厚度为基于涂层的层厚度达至大约+/-20%,优选地达至+/-10%。
已知方案的缺点在于,防腐蚀和抗磨损涂层涂覆在制动盘的摩擦表面的表面上,并且在多次第一制动操作中,该涂层很快会被摩擦掉,从而使得摩擦表面很快会被腐蚀,并且腐蚀过程会直接损坏基体材料。特别是对于电动车辆或混合动力车辆,例如,可以预计清洁制动操作的次数会大大减少,这会导致腐蚀加剧,从而不可避免地造成故障。这些故障表现为噪音问题,并且在极端情况下可能导致制动性能丧失。此外,另一个缺点在于,由于在摩擦表面的区域内发生的腐蚀,可能会使得摩擦表面磨损得更快。
又一缺点是涂覆有硬质材料的制动盘的材料成本和生产成本高,其中制动盘的层***基于碳化物,例如碳化钨、碳化铬或碳化硼。
发明内容
本发明的目的是提供一种耐用的制动盘,其防腐蚀性和抗磨损性得到了提高。
该目的通过专利权利要求书中详述的发明来实现。有利的配置是从属权利要求的主题,并且本发明还包括各个从属专利权利要求通过“和”联系的组合,前提是它们不相互排斥。
本发明的目的通过一种制动盘来实现,所述制动盘具有由钢或灰铸铁制成的金属主体,所述金属主体具有至少一个形成有摩擦表面的区域和至少一个形成有接触表面的区域,所述接触表面用于固定制动盘,其中,在所述金属主体内,至少在所述摩擦表面的区域中,存在由铁、铝和硅形成的扩散层,该扩散层具有0.1mm至0.6mm的层厚度,并且通过扩散过程与所述金属主体的钢或灰铸铁相互作用而形成所属扩散层。
有利地,制动盘还包括通风管道。
在有利配置中,所述扩散层在层厚度上呈由铁和铝构成的渐变层***的形式,其中硅在所述渐变层***中均匀分布,其中,特别有利的是,所述渐变层***按以下方式形成:铁的比例朝着层表面不断减少,而铝的比例朝着层表面不断增加。
有利的是,所述至少一个扩散层通过用AlSi12和/或AlSi6合金涂覆所述金属主体、然后进行热处理而形成。
同样有利的是,所述接触表面和/或所述通风管道的区域也具有所述扩散层。
还有利的是,与所述金属主体的材料的硬度相比,所述扩散层的硬度更大。
在制动盘的有利实施中,所述扩散层通过在250℃至650℃下进行热处理而形成,其中处理时长为40分钟至300分钟。
有利地,所述通风管道具有扩散层和层厚度为0.01mm至0.4mm的Al基表面层。
还有利的是,至少在扩散层内存在着色物质。
本发明还通过一种用于生产本发明的制动盘的方法来实现,其中,至少在形成有摩擦表面的区域中对所述金属主体的表面进行机械加工,然后通过涂覆过程至少在形成有摩擦表面的区域中设置AlSi基合金,之后在保护性气氛下对所述制动盘进行热处理,最后至少在所述摩擦表面的区域中对所述金属主体的表面进行机械加工。
有利地,所述接触表面和/或所述通风管道也涂覆有AlSi基合金。
还有利的是,使用AlSi12或AlSi6合金实施所述涂覆。
在所述方法的有利配置中,在保护性气氛下进行所述机械加工和/或所述涂覆过程。
在所述方法的进一步有利配置中,所述制动盘的热处理在250℃至650℃的温度下、特别有利地在550℃至600℃的温度下进行,并且处理时长为40分钟至300分钟。
在所述方法的进一步有利配置中,在涂覆之前,在保护性气氛下,将所述制动盘预热至250℃至650℃的温度。
此外,在所述方法的有利配置中,在涂覆之前,在没有保护性气氛的情况下,将所述制动盘预热至150℃至200℃的温度。
并且,还有利的是,所述涂覆借助于电弧丝喷涂、溅滴的动能增加的改进电弧丝喷涂、高速丝火焰喷涂、液态铝浸渍、油漆浸渍、油漆喷涂、激光粉末堆焊、粉末喷涂或电泳涂覆实施。
另外有利的是,在使用油漆涂覆之后,将所述制动盘首先在5秒至240秒的时间段内感应加热至250℃至650℃的温度。
并且另外有利的是,在所述涂覆之前或期间加入着色物质,这些着色物质用于至少在摩擦表面(2)的区域中的所述扩散层(3)内形成颜色标记。
本发明首次成功地提供了一种防腐蚀性和抗磨损性得到提高的制动盘,所述制动盘是在金属主体上没有任何附加层的情况下生产的。至少在摩擦表面的区域中实现了防腐性和抗磨损性的提高,并且接触表面和/或通风管道的区域也可以创造性地具有防腐性和抗磨损性。
在本发明的上下文中,制动盘应理解为意指制动***的部件,该部件由金属主体和不同的功能区域(诸如在直径方向上布置的摩擦表面、接触表面、以及由桥接件(Stege)形成的通风管道)构成。
在本发明的上下文中,金属主体应理解为意指根据本发明生产的、由钢或灰铸铁制成的、具有功能区域的制动盘。
在本发明的上下文中,摩擦表面应理解为意指一体式或两部件式圆盘状表面,经由该表面结合适当形成的制动衬面一起实现制动作用。
在本发明的上下文中,接触表面应理解为意指金属主体的与车轮的轮缘和/或与车轮轴承或轴接触并且通常与其凝聚结合(kraftschlüssig verbunden)的区域。
在本发明的上下文中,通风管道应理解为意指金属主体的在两个摩擦表面之间形成的区域,该区域具有从制动盘排出热量并且从而冷却制动盘的效果。通风管道由连接摩擦表面的在直径上相对置的区域的桥接件形成。通风管道也可以形成为摩擦表面上的孔或槽。
根据本发明,至少摩擦表面的区域具有AlSi基扩散层,所述AlSi基扩散层具有0.1mm至0.6mm的层厚度并且通过与金属主体的钢或灰铸铁相互作用而形成该扩散层,因此,制动盘的防腐蚀性和抗磨损性得到显著提高。
已经发现,在制动盘的涂覆中,形成氧化铁不利于形成防腐蚀性和抗磨损性,因为金属主体表面上形成的氧化铁会使粘附条件恶化,其首先阻碍或防止铁铝化合物的形成,其次还会致使抗磨损和防腐蚀层发生脆性剥落。
为了防止这种情况发生,根据本发明,建议在第一过程步骤中,在使用AlSi基合金进行涂覆之前,至少在摩擦表面的区域中对金属主体进行机械加工,并且有利地提出,机械加工应为在旋转方向上和与旋转方向相反的方向上采用刚玉进行的两次喷砂操作,喷砂角度为约45°。这至少在摩擦表面的区域中增加了表面积,从而改善了待形成的抗磨损和防腐蚀层的粘附和扩散条件。
特别有利的是,在保护性气氛下对金属主体材料进行机械加工,以防止在对表面进行机械加工期间和之后直接形成氧化铁。所使用的保护性气体例如可以是氩气或氮气。特别有利的是,另外还提出,所有过程步骤都应在保护性气氛下进行,以避免任何不利于本发明的扩散层的期望生长和0.1mm至0.6mm的期望层厚度的氧化过程。
根据本发明提出,在对金属主体的表面进行机械加工之后,至少在摩擦表面的区域中将AlSi基合金涂覆于金属主体的材料。有利地,金属主体同样可以在保护性气氛下涂覆AlSi基合金,也以防止形成氧化铁。
使用热涂覆过程,使得可以至少在摩擦表面的区域中形成具有良好粘附性的晶粒特别细的AlSi基层,以便随后能够通过热处理在金属主体的材料中实现本发明的扩散层。
根据本发明已经发现,利用AlSi基合金组合物作为涂覆材料,实现了特别有利的抗磨损性和防腐蚀性,AlSi基合金组合物通过在金属主体的材料内扩散并在250℃至650℃、优选550℃至600℃的温度下进行本发明的热处理且处理时间为40分钟至300分钟而产生,并且令人惊讶地的是,该AlSi基合金组合物在重复的制动操作中能够持续保持。
在550℃至600℃的有利温度范围内,扩散层形成过程中扩散速率增加,同时,所涂覆的材料保持在熔点以下。避免了所涂覆的AlSi基合金流出金属主体。
对于触发扩散过程,特别有利的是,在涂覆之前在保护性气氛下将制动盘预热至250℃至650℃的温度。已经发现,通过使用保护性气氛,防止了在预热过程中在高于200℃的温度下形成不需要的氧化铁。
令人惊讶的是,当将预热温度仅设置为150℃至200℃时,可以避免在制动盘的预热中使用保护性气体。
然而,根据本发明,从铁、铝和硅生长的扩散层不是设置在金属主体的表面上的抗磨损和防腐蚀层(如根据现有技术已知的)。相反,至少在摩擦表面的区域中,仅通过纯扩散层实现抗磨损性和防腐蚀性,通过扩散过程对涂覆在金属主体上的AlSi基合金进行受控热处理形成了该纯扩散层。
根据本发明,已经发现,令人惊讶的是,在热处理期间作为合金成分的硅的比例使得在扩散层中能够均匀沉积硅晶体,这些硅晶体结合铝形成了特别均匀且坚硬的扩散层。在AlSi基合金中发现的硅的比例还具有另一个优点:氧以特别有利的方式结合,因此防止了金属主体的材料通过形成氧化铁而发生氧化过程。防止形成氧化铁可使铁铝化合物在主体材料中不停地快速生长,其中层厚度为0.1mm至0.6mm。
此外,已经发现,所提出的硅比例防止了铝在摩擦表面的表面附近区域中发生不必要的氧化。这降低了渗入到扩散层中的氧气的含量,从而通过使用的硅比例可以阻止所需铁铝化合物在AlSi基合金中的有效生长。
对于随后通过扩散形成的层的质量而言,重要的是,所涂覆的AlSi基层具有最大的固有不透过性并且能很好地润湿金属主体的表面。为此,有利的是,待涂覆的AlSi基合金的熔滴(溅滴)以高动能撞击金属主体的表面。这尤其是通过以下涂覆方法实现的:电弧丝喷涂、溅滴的动能增加的改进电弧丝喷涂、高速火焰喷涂(HVOF)或高速丝材火焰喷涂。
通过热引发扩散过程获得由铁铝化合物形成的、表面硬度显著较高的扩散层。通常用于金属主体的材料是钢或灰铸铁,其表面硬度为约220HV。
令人惊讶的是,通过将AlSi基合金扩散到金属主体的材料中,导致至少在后机械处理的摩擦表面上,具有350HV至850HV的显著较高的表面硬度。此处所确定的硬度是在整个扩散区内确定的。扩散层中确定的硬度的特殊技术效果在于实现了制动盘磨损的减少,其对于制动盘的使用寿命具有积极效果,并且还使细粉尘的排放显著减少。
所形成的扩散层的另一个优点是,无需促进金属主体与涂覆在其上的抗磨损层或防腐蚀层之间的粘附力,因为AlSi基合金直接涂覆在金属主体的材料上,经由与金属主体的材料的金属间化合过程,AlSi基合金通过热引发的扩散过程在金属主体上作为铁铝化合物直接生长。从而防止抗磨损和防腐蚀层从金属主体的表面剥落或与其分离。
此外,扩散层、以及制动衬面、制动盘和制动卡钳之间的相互作用会使阻尼系数和固有频率发生正向偏移。通过扩散深度和硬度的设置,制动盘的功能特性得到积极改善。固有频率和阻尼系数降低,因此至少在制动操作中减少了专家所称的制动盘的抖动和噪音。
已经发现,使用AlSi基合金涂覆金属主体的特别有利的过程为电弧喷涂、浸渍、喷漆、激光粉末堆焊或粉末喷涂,尤其是在涂覆AlSi基合金之前对金属主体进行加热。在先加热金属主体会更快启动扩散过程,并促进铁铝化合物在金属主体内生长。
热处理后对摩擦表面以及接触表面的区域中的表面进行最终机械加工实现了以下技术效果:消除了过量的Al基表面层,并且与已知的气体氮化制动盘相比,本发明的制动盘可与NAO(无石棉有机)制动衬面和低金属含量制动衬面一起使用。
另外,最终机械加工还可以以简单的方式纠正制动盘的任何可能翘曲,而不会影响提高的抗磨损性和防腐蚀性。此外,最终机械加工实现了以下效果:可以省去消除不平衡的额外操作。
这种新型制动盘克服了目前市场上的制动盘的非常显著的缺点。例如,已知的是,制动衬面的高度小于制动盘的摩擦表面的高度。
因此,已知的制动盘具有围绕摩擦表面的外周延伸的倒角,以防止制动衬面延伸进入摩擦表面,并且避免了随后从制动单元上拆卸摩擦衬片的困难和不便。然而,在摩擦表面的外周上形成倒角与摩擦表面的生产中的额外操作相关联,因此也会增加制造成本。
本发明的制动盘至少在摩擦表面的区域中的由铁铝化合物形成的AlSi基扩散层克服了这一缺点,因为350HV至850HV的特别硬度防止了制动衬面延伸进入摩擦表面内。
在本发明的有利实施中,在制动盘中,不仅摩擦表面而且接触表面和通风管道的区域都可以具有本发明的AlSi基合金,并且可以形成本发明的扩散层。
在接触表面的区域中实现抗磨损性和防腐蚀性具有以下技术优势:例如,对于制动盘,其在与车辆的车轴凝聚结合中的沉降特性明显降低。这防止了制动盘在其与车轮螺栓接触之前滑动。
在通风管道的区域中形成抗磨损性和防腐蚀性具有以下效果:由于通风管道不易被腐蚀(尤其是在冬季与盐溶液接触时),因此通风管道的表面能够保持光滑,能够通过通风管道进行持续无障碍的流动,从而能够在制动操作中持续良好地散热。
对于由连接桥接件形成的通风管道,通过将AlSi基合金热引发扩散到铸造材料或钢材料中,可以首次使得连接桥接件的壁厚较小。已知的是,考虑到由于缺乏防腐蚀性而因此导致的磨损增加,现有技术中已知的连接桥接件必须具有5mm的最小壁厚。
本发明在通风管道的区域中具有抗磨损性和防腐蚀性,使得最小几何结构显著减少了约40%至50%,因此首次提供了重量优化且成本更低的制动盘。
可以想到,本发明仅对制动盘的涂覆有AlSi基合金的局部区域进行特定热处理。这实现了启动扩散过程的效果,从而仅在这些区域对制动盘进行特定功能化。例如,可以仅在金属主体的材料的区域中进行特定热处理,以改善该区域的抗磨损性和防腐蚀性。因此,不需要对整个制动盘进行完整的热处理,这使得本发明的制动盘的生产成本更低,并且生产时间更短。
在制动盘和生产过程的特别有利配置中,在进行涂覆之前或期间提供着色物质,使用着色物质在扩散层内形成颜色标记。这实现了以下效果:特别是在摩擦表面的区域中,在扩散层中形成了彩色阴影,所述彩色阴影可以用作例如磨损指示器。但着色物质也可以是温度指示器,并且提供关于制动盘(例如摩擦表面)的工作温度的信息。
附图说明
下文将通过实施例详细阐述本发明。
图1示出了制动盘的横截面示意图;以及
图2示出了具有扩散层的制动盘的局部示意图。
具体实施方式
实施例
提供了一种用于车辆的内部通风式制动盘,该制动盘由灰铸铁制成,硬度为220HV。该制动盘具有两个在直径上相对置布置的摩擦表面2和用于将制动盘固定至车轴的接触表面6。两个摩擦表面2由呈桥接件形式的通风管道4连接。通过使用刚玉(含有99.81%的Al2O3、0.1%的Na2O、0.04%的TiO2、0.02%的SiO2、0.03%的Fe2O3)和保护性氮气气氛,两个摩擦表面2的表面以45°角沿制动盘的旋转方向以及与旋转方向相反的方向进行两次机械加工,从而去除污物和氧化铁,以便为后续形成扩散层提供更有利的扩散条件。此外,在表面附近的区域中对灰铸铁的层状结构进行改性并消除层状结构。
随后,将制动盘输送至涂覆设备,并在保护性氮气气氛下借助于电弧丝喷涂在摩擦表面2、接触表面6和通风管道4的区域中使用层厚度为0.4 mm的AlSi12合金对制动盘进行涂覆。在涂覆之后,在保护性氩气气氛下,在炉中对整个制动盘进行热处理。该热处理在580℃下进行240分钟,然后冷却制动盘。通过热处理,形成层厚度为170µm至200µm的铁铝化合物的扩散层3和层厚度为约50µm的铝基表面层。
然后,通过在摩擦表面2和接触表面6的区域中进行研磨,对多余的Al基表面层进行机械加工,并去除扩散层3之上的多余的Al基表面层,使得仅由生长的铁铝化合物组成的扩散层3保留在摩擦表面2和接触表面6的区域中。硅在扩散层中均匀分布。在通风管道4的区域中,没有对表面进行机械加工。
摩擦表面2、接触表面6和通风管道4的硬度为350HV,并且具有持久的抗磨损性和防腐蚀性。
附图标记列表
1-金属主体
2-摩擦表面
3-扩散层
4-通风管道
5-旋转轴
6-接触表面。
Claims (21)
1.一种制动盘,该制动盘具有由钢或灰铸铁制成的金属主体(1),所述金属主体(1)具有至少一个形成有摩擦表面(2)的区域和至少一个形成有接触表面(6)的区域,所述接触表面(6)用于固定所述制动盘,其中,在所述金属主体(1)内,至少在所述摩擦表面(2)的所述区域中,存在由铁、铝和硅形成的扩散层(3),该扩散层(3)具有0.1mm至0.6mm的层厚度,并且通过扩散过程与所述金属主体(1)的钢或灰铸铁相互作用而形成所述扩散层(3),
所述扩散层(3)在层厚度上呈由铁和铝构成的渐变层***的形式,其中硅在所述渐变层***中均匀分布,其中,所述渐变层***按以下方式形成:铁的比例朝着层表面不断减少,而铝的比例朝着所述层表面不断增加,其中硅在所述渐变层***中均匀分布。
2.根据权利要求1所述的制动盘,其中,该制动盘还包括通风管道。
3.根据权利要求1或2所述的制动盘,其中,所述至少一个扩散层(3)通过用AlSi12和/或AlSi6合金涂覆所述金属主体(1)、然后进行热处理而形成。
4.根据权利要求2所述的制动盘,其中,所述接触表面(6)和/或所述通风管道(4)的区域也具有所述扩散层(3)。
5.根据权利要求1或2所述的制动盘,其中,与所述金属主体(1)的材料的硬度相比,所述扩散层(3)的硬度更大。
6.根据权利要求1或2所述的制动盘,其中,所述扩散层(3)通过在250℃至650℃下进行热处理而形成,处理时长为40分钟至300分钟。
7.根据权利要求2所述的制动盘,其中,所述通风管道(4)具有所述扩散层(3)和层厚度为0.01mm至0.4mm的Al基表面层。
8.根据权利要求1或2所述的制动盘,其中,至少在所述扩散层(3)内存在着色物质。
9.一种用于生产根据权利要求1所述的制动盘的方法,其中,至少在形成有所述摩擦表面(2)的区域中对所述金属主体(1)的表面进行机械加工,然后通过涂覆过程至少在形成有所述摩擦表面(2)的所述区域中设置AlSi基合金,之后在保护性气氛下对所述制动盘进行热处理,最后至少在所述摩擦表面(2)的所述区域中对所述金属主体(1)的所述表面进行机械加工。
10.一种用于生产根据权利要求2至8中任一项所述的制动盘的方法,其中,至少在形成有所述摩擦表面(2)的区域中对所述金属主体(1)的表面进行机械加工,然后通过涂覆过程至少在形成有所述摩擦表面(2)的所述区域中设置AlSi基合金,之后在保护性气氛下对所述制动盘进行热处理,最后至少在所述摩擦表面(2)的所述区域中对所述金属主体(1)的所述表面进行机械加工。
11.根据权利要求9所述的方法,其中,所述接触表面(6)也涂覆有AlSi基合金。
12.根据权利要求10所述的方法,其中,所述通风管道(4)也涂覆有AlSi基合金。
13.根据前述权利要求9至12中任一项所述的方法,其中,使用AlSi12或AlSi6合金实施所述涂覆。
14.根据权利要求9至12中任一项所述的方法,其中,在保护性气氛下进行所述机械加工和/或所述涂覆过程。
15.根据前述权利要求9至12中任一项所述的方法,其中,所述制动盘的热处理在250℃至650℃的温度下进行,并且处理时长为40分钟至300分钟。
16.根据前述权利要求9至12中任一项所述的方法,其中,所述制动盘的热处理在550℃至600℃的温度下进行,并且处理时长为40分钟至300分钟。
17.根据前述权利要求9至12中任一项所述的方法,其中,在涂覆之前,在保护性气氛下,将所述制动盘预热至250℃至650℃的温度。
18.根据前述权利要求9至12中任一项所述的方法,其中,在涂覆之前,在没有保护性气氛的情况下,将所述制动盘预热至150℃至200℃的温度。
19.根据前述权利要求9至12中任一项所述的方法,其中,所述涂覆借助于电弧丝喷涂、溅滴的动能增加的改进电弧丝喷涂、高速丝火焰喷涂、液态铝浸渍、油漆浸渍、油漆喷涂、激光粉末堆焊、粉末喷涂或电泳喷涂实施。
20.根据权利要求19所述的方法,其中,在使用油漆涂覆之后,将所述制动盘首先在5秒至240秒的时间段内感应加热至250℃至650℃的温度。
21.根据前述权利要求9至12中任一项所述的方法,其中,在所述涂覆之前或期间加入着色物质,这些着色物质用于至少在所述摩擦表面(2)的所述区域中的所述扩散层(3)内形成颜色标记。
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JP2023508776A (ja) | 2023-03-03 |
CN115190916A (zh) | 2022-10-14 |
PL4085158T3 (pl) | 2023-11-06 |
HUE062847T2 (hu) | 2023-12-28 |
SI4085158T1 (sl) | 2023-10-30 |
ES2955177T3 (es) | 2023-11-29 |
MX2022008194A (es) | 2022-09-23 |
HRP20231017T1 (hr) | 2023-12-08 |
EP4085158B1 (de) | 2023-05-31 |
US20230046519A1 (en) | 2023-02-16 |
WO2021008744A1 (de) | 2021-01-21 |
KR20220123063A (ko) | 2022-09-05 |
EP4085158A1 (de) | 2022-11-09 |
BR112022013193A2 (pt) | 2022-09-13 |
DE202019107269U1 (de) | 2020-01-23 |
PT4085158T (pt) | 2023-08-23 |
JP7463554B2 (ja) | 2024-04-08 |
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