CN115368137A - 一种铜碳石墨复合材料的制备工艺 - Google Patents
一种铜碳石墨复合材料的制备工艺 Download PDFInfo
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Abstract
本发明涉及电接触用金属碳石墨复合材料的制备,特别提供了一种用等静压成型生产碳石墨毛坯再浸渍铜合金形成铜碳石墨复合材料的方法,包括如下步骤:S1、原料,熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉等;S2、干粉混捏,将S1中原料按一定比例混匀;S3、沥青粘接,将S2中混好的原料与改质熔化沥青按一定比例混匀;S4、轧片,将S3中原料通过辊轧机压制成薄片;S5、磨粉,将S4得到的粉料在磨粉机上磨粉;S6、成型,将S5磨好的料粉在液压冷等静压机上成型;S7、焙烧,浸渍沥青后,再次焙烧;S8、浸金属;S9、后续加工成型。本发明与现有技术相比,具有生产效率高,产品性能优异,无环境污染等优点。
Description
技术领域
本发明涉及电接触用金属碳石墨复合材料的制备,特别提供了一种用等静压成型生产碳石墨毛坯再浸渍铜合金形成铜碳石墨复合材料的方法。
背景技术
铜石墨复合材料融合了金属铜(合金)优良的导电性、高强度、高塑性和石墨显著的耐热性、耐腐蚀性、润滑性等性能,综合性能突出,是一种具有广阔应用前景的新型功能材料。铜石墨复合材料广泛的应用于滑动电接触材料、耐磨材料、大规模集成电路和大功率微波器件中导电导热功能材料等领域,特别是在工作环境比较严酷的电器开关触头、电刷、电力机车受电弓滑板等环境下发挥着重要作用。
当前铜石墨复合材料的制备工艺多种多样,具有实际应用价值的制备方法仅少数几种,如粉末冶金法、浸渍法等。要保证铜石墨复合材料的导电性和自润滑性一般都会采取浸渍工艺,石墨制品浸渍金属后,碳基体气孔中充填了金属,形成金属网状增强骨架,起到提高碳基体强度和韧性的作用。浸渍金属后导电和导热性能明显改善,仍可保持碳基体固有的润滑性能,能在接触表面上形成润滑膜,显著降低材料磨耗。但是目前的碳石墨坯料浸金属工艺较为复杂,金属与碳基体之间的结合力有待提高,碳基体的性能波动较大,导致最终制品的性能稳定性有待改善。
因此,申请人提出一种铜碳石墨复合材料的制备工艺,其制备的铜碳石墨复合材料各项性能指标能满足各种使用要求,且操作方便,生产效率高,环境友好。
发明内容
基于现有技术的不足,本发明提供了一种铜碳石墨复合材料的制备工艺。
具体为,本发明提供的一种铜碳石墨复合材料的制备工艺,包括如下具体步骤:
S1、原料,熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉,铜锡合金(Cu80-90%、Sn10-20%);
所述熟沥青焦粉,粒度3-10μm,灰分≤0.8%、含硫量≤0.3%、挥发份≤1.5%;
所述精炼石墨粉,粒度-320目:70-90%,+200目≤1.0%,灰分≤0.5%,挥发分≤1.0%;
所述高耐磨炭黑,灰分≤0.7%、吸碘值82±7g/Kg、DBP吸收值(102±7)×10-5m3/kg;
所述氧化物陶瓷粉,粒度5-10μm,有效氧化物含量≥85%,真密度≥2.2g/cm3,水分≤0.5%;
所述改质沥青的软化点105-120℃,结焦值为≥50%,灰分≤0.50%;
S2、干粉混捏,将熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉按79-83:6-10:4-8:3-7重量份数比混合均匀;
S3、沥青粘接,将S2中混好的原料与改质熔化沥青按重量份数比10:3-5混合,搅拌均匀;
S4、轧片,将S3中搅拌均匀的原料通过辊轧机压制成薄片,片厚≤0.5mm,轧辊轧制次数不低于2次;
S5、磨粉,将S4得到的粉料在磨粉机上磨粉,磨好粉料粒度-320目≥80%;
S6、成型,将S5磨好的料粉在液压冷等静压机上成型,成型压力≥120MPa,保压≥40分钟,卸压后得到毛坯生料;
S7、焙烧,将S6制备好的毛坯生料放入焙烧炉中进行焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按4℃/h升温,保持12小时;
750-900℃,按8℃/h升温,保持6小时;
900-1200℃,按12℃/h升温,保持5小时;
自然冷却后,获得一焙毛坯料;
将一焙毛坯料浸渍沥青,浸渍压力1.6 Mpa,再进行二次焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按6℃/h升温,保持9小时;
750-900℃,按10℃/h升温,保持6小时;
900-1200℃,按13℃/h升温,保持4小时;
1200-1800℃,按15℃/h升温,保持4小时;
自然冷却后,获得二焙碳基坯料;
S8、浸金属,焙烧后的碳基坯料在1200℃电炉中预热2小时,将铜锡合金加入中频炉中,加热至1300℃,使其完全熔化成熔体,将熔体倒入碳基坯料中,确保熔体漫过碳基坯料,加热至1300-1400℃,采用机械加压方式或抽真空加压方式,压力维持10-24Mpa,保压时间不低于2分钟,倒出合金熔体,自然冷却至室温;
S9、将浸金属完成后的坯料取出,加工成所需尺寸精度即可。
本发明的有益效果是:能有效改善金属与碳石墨基体间的界面浸润性,提高制品的浸透率;能较方便的制备不同规格尺寸的制品;制品性能优异,操作简便,生产效率高,环境友好。
具体实施方式
实施例一
一种铜碳石墨复合材料的碳基坯料制备工艺,包括如下具体步骤:
S1、原料,熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉等;
所述熟沥青焦粉,粒度3-10μm,灰分≤0.8%、含硫量≤0.3%、挥发份≤1.5%;
所述精炼石墨粉,粒度-320目:70-90%,+200目≤1.0%,灰分≤0.5%,挥发分≤1.0%;
所述高耐磨炭黑,灰分≤0.7%、吸碘值82±7g/Kg、DBP吸收值102±710-5m3/kg;
所述氧化物陶瓷粉,粒度5-10μm,有效氧化物含量≥85%,真密度≥2.2g/cm3,水分≤0.5%;
所述改质沥青的软化点105-120℃,结焦值为≥50%,灰分≤0.50%;
S2、干粉混捏,将熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉按79:8:8:5重量份数比混合均匀;
S3、沥青粘接,将S2中混好的原料与改质熔化沥青按重量份数比10:4.2混合,搅拌均匀;
S4、轧片,将S3中搅拌均匀的原料通过辊轧机压制成薄片,片厚≤0.5mm,轧辊轧制次数不低于2次;
S5、磨粉,将S4得到的粉料在磨粉机上磨粉,磨好粉料粒度-320目≥80%;
S6、成型,将S5磨好的料粉在液压冷等静压机上成型,成型压力≥120MPa,保压≥40分钟,卸压后得到毛坯生料;
S7、焙烧,将S6制备好的毛坯生料放入焙烧炉中进行焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按4℃/h升温,保持12小时;
750-900℃,按8℃/h升温,保持6小时;
900-1200℃,按12℃/h升温,保持5小时;
自然冷却后,获得一焙毛坯料;
将一焙毛坯料浸渍沥青,浸渍压力1.6 Mpa,再进行二次焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按6℃/h升温,保持9小时;
750-900℃,按10℃/h升温,保持6小时;
900-1200℃,按13℃/h升温,保持4小时;
1200-1800℃,按15℃/h升温,保持4小时;
自然冷却后,获得二焙碳基坯料;
在混合过程中采用改质沥青做粘接剂,在相同的焙烧温度下,碳制品性能更加优越。该工艺中加入改质沥青做粘接剂与中温沥青对照组焙烧性能比较如下。
实施例二
一种铜碳石墨复合材料的制备工艺,包括如下具体步骤:
S1、原料,熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉,铜锡合金(Cu90%、Sn10%);
所述熟沥青焦粉,粒度3-10μm,灰分≤0.8%、含硫量≤0.3%、挥发份≤1.5%;
所述精炼石墨粉,粒度-320目:70-90%,+200目≤1.0%,灰分≤0.5%,挥发分≤1.0%;
所述高耐磨炭黑,灰分≤0.7%、吸碘值82±7g/Kg、DBP吸收值102±710-5m3/kg;
所述氧化物陶瓷粉,粒度5-10μm,有效氧化物含量≥85%,真密度≥2.2g/cm3,水分≤0.5%;
所述改质沥青的软化点105-120℃,结焦值为≥50%,灰分≤0.50%;
S2、干粉混捏,将熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉按80:8:6:6重量份数比混合均匀;
S3、S3、沥青粘接,将S2中混好的原料与改质熔化沥青按重量份数比10:4混合,搅拌均匀;
S4、轧片,将S3中搅拌均匀的原料通过辊轧机压制成薄片,片厚≤0.5mm,轧辊轧制次数不低于2次;
S5、磨粉,将S4得到的粉料在磨粉机上磨粉,磨好粉料粒度-320目≥80%;
S6、成型,将S5磨好的料粉在液压冷等静压机上成型,成型压力≥120MPa,保压≥40分钟,卸压后得到毛坯生料;
S7、焙烧,将S6制备好的毛坯生料放入焙烧炉中进行焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按4℃/h升温,保持12小时;
750-900℃,按8℃/h升温,保持6小时;
900-1200℃,按12℃/h升温,保持5小时;
自然冷却后,获得一焙毛坯料;
将一焙毛坯料浸渍沥青,浸渍压力1.6 Mpa,再进行二次焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按6℃/h升温,保持9小时;
750-900℃,按10℃/h升温,保持6小时;
900-1200℃,按13℃/h升温,保持4小时;
1200-1800℃,按15℃/h升温,保持4小时;
自然冷却后,获得二焙碳基坯料;
S8、浸金属,焙烧后的碳基坯料在1200℃电炉中预热2小时,将铜锡合金加入中频炉中,加热至1300℃,使其完全熔化成熔体,将熔体倒入碳基坯料中,确保熔体漫过碳基坯料,加热至1300-1400℃,采用抽真空加压方式,压力维持10Mpa以上,保压时间不低于1.5分钟,倒出合金熔体,自然冷却至室温;
S9、将浸金属完成后的坯料取出,加工成所需尺寸精度即可。
采用上述工艺,二次焙烧后经1600-1800℃高温处理,石墨化程度可达48%左右,制品机械强度大大提高,制品的开口气孔率>12%,气孔率降低近50%,浸渍效果更佳,具体性能参数如下表所示。
实施例三
一种铜碳石墨复合材料的制备工艺,包括如下具体步骤:
S1、原料,熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉,铜锡合金(Cu80-90%、Sn10-20%);
所述熟沥青焦粉,粒度3-10μm,灰分≤0.8%、含硫量≤0.3%、挥发份≤1.5%;
所述精炼石墨粉,粒度-320目:70-90%,+200目≤1.0%,灰分≤0.5%,挥发分≤1.0%;
所述高耐磨炭黑,灰分≤0.7%、吸碘值82±7g/Kg、DBP吸收值102±710-5m3/kg;
所述氧化物陶瓷粉,粒度5-10μm,有效氧化物含量≥85%,真密度≥2.2g/cm3,水分≤0.5%;
所述改质沥青的软化点105-120℃,结焦值为≥50%,灰分≤0.50%;
S2、干粉混捏,将熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉按82:7:6:5重量份数比混合均匀;
S3、S3、沥青粘接,将S2中混好的原料与改质熔化沥青按重量份数比10:3.9混合,搅拌均匀;
S4、轧片,将S3中搅拌均匀的原料通过辊轧机压制成薄片,片厚≤0.5mm,轧辊轧制次数不低于2次;
S5、磨粉,将S4得到的粉料在磨粉机上磨粉,磨好粉料粒度-320目≥80%;
S6、成型,将S5磨好的料粉在液压冷等静压机上成型,成型压力≥120MPa,保压≥40分钟,卸压后得到毛坯生料;
S7、焙烧,将S6制备好的毛坯生料放入焙烧炉中进行焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按4℃/h升温,保持12小时;
750-900℃,按8℃/h升温,保持6小时;
900-1200℃,按12℃/h升温,保持5小时;
自然冷却后,获得一焙毛坯料;
将一焙毛坯料浸渍沥青,浸渍压力1.6 Mpa,再进行二次焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按6℃/h升温,保持9小时;
750-900℃,按10℃/h升温,保持6小时;
900-1200℃,按13℃/h升温,保持4小时;
1200-1800℃,按15℃/h升温,保持4小时;
自然冷却后,获得二焙碳基坯料;
S8、浸金属,焙烧后的碳基坯料在1200℃电炉中预热2小时,将铜锡合金加入中频炉中,加热至1300℃,使其完全熔化成熔体,将熔体倒入碳基坯料中,确保熔体漫过碳基坯料,加热至1300-1400℃,采用机械加压方式,压力维持24Mpa以上,保压时间不低于3分钟,倒出合金熔体,自然冷却至室温;
S9、将浸金属完成后的坯料取出,加工成所需尺寸精度即可。
采用上述工艺,制品装罐时应留有一定间隙,保持3-5mm距离。在罐中,铜合金熔体的高度应高出制品高度15mm以上。上述碳石墨毛坯浸渍不同Cu-Sn合金性能比较如下表所示。
以上所述仅为本发明的较佳实施例,可以理解的是,上述实施例是示例性的,不能理解为对本发明专利的限制。在权利要求书所描述的范围内,本领域技术人员不经创造性劳动即可作出的各种修改和变形仍属本专利的保护范围。
Claims (6)
1.一种铜碳石墨复合材料的制备工艺,其特征在于,包括以下步骤:
S1、原料,熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉,铜锡合金;
S2、干粉混捏,将熟沥青焦粉,精炼石墨粉,高耐磨炭黑,氧化物陶瓷粉按79-83:6-10:4-8:3-7重量份数比混合均匀;
S3、沥青粘接,将S2中混好的原料与改质熔化沥青按重量份数比10:3-5混合,搅拌均匀;
S4、轧片,将S3中搅拌均匀的原料通过辊轧机压制成薄片,片厚≤0.5mm,轧辊轧制次数不低于2次;
S5、磨粉,将S4得到的粉料在磨粉机上磨粉,磨好粉料粒度-320目≥80%;
S6、成型,将S5磨好的料粉在液压冷等静压机上成型,成型压力≥120MPa,保压≥40分钟,卸压后得到毛坯生料;
S7、焙烧,将S6制备好的毛坯生料放入焙烧炉中进行焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按4℃/h升温,保持12小时;
750-900℃,按8℃/h升温,保持6小时;
900-1200℃,按12℃/h升温,保持5小时;
自然冷却后,获得一焙毛坯料;
将一焙毛坯料浸渍沥青,浸渍压力1.6 Mpa,再进行二次焙烧,其温度控制方式如下:
室温-300℃,自由升温,保持2小时;
300-750℃,按6℃/h升温,保持9小时;
750-900℃,按10℃/h升温,保持6小时;
900-1200℃,按13℃/h升温,保持4小时;
1200-1800℃,按15℃/h升温,保持4小时;
自然冷却后,获得二焙碳基坯料;
S8、浸金属,焙烧后的碳基坯料在1200℃电炉中预热2小时,将铜锡合金加入中频炉中,加热至1300℃,使其完全熔化成熔体,将熔体倒入碳基坯料中,确保熔体漫过碳基坯料,加热至1300-1400℃,采用抽真空加压方式,压力维持10Mpa以上,保压时间不低于1.5分钟,倒出合金熔体,自然冷却至室温;
S9、将浸金属完成后的坯料取出,加工成所需尺寸精度即可。
2.如权利要求1所述的一种铜碳石墨复合材料的制备工艺,其特征在于:所述铜锡合金中各成分含量为:Cu80-90%、Sn10-20%;
所述熟沥青焦粉,粒度3-10μm,灰分≤0.8%、含硫量≤0.3%、挥发份≤1.5%;
所述精炼石墨粉,粒度-320目:70-90%,+200目≤1.0%,灰分≤0.5%,挥发分≤1.0%;
所述高耐磨炭黑,灰分≤0.7%、吸碘值82±7g/Kg、DBP吸收值(102±7)×10-5m3/kg;
所述氧化物陶瓷粉,粒度5-10μm,有效氧化物含量≥85%,真密度≥2.2g/cm3,水分≤0.5%;
所述改质沥青的软化点105-120℃,结焦值为≥50%,灰分≤0.50%。
3.如权利要求1所述的一种铜碳石墨复合材料的制备工艺,其特征在于,S3中采取改质沥青作为粘接剂,能有效提高碳基坯料性能。
4.如权利要求1所述的一种铜碳石墨复合材料的制备工艺,其特征在于,S6中根据等静压模具尺寸不同,可以得到不同尺寸规格的碳基坯料。
5.如权利要求1所述的一种铜碳石墨复合材料的制备工艺,其特征在于,S7中焙烧工艺采取高温焙烧及加压浸渍处理,大幅提高碳基坯料性能,有效提高浸渍效率。
6.如权利要求1所述的一种铜碳石墨复合材料的制备工艺,其特征在于,S8中采用铜锡合金可有效避免铅、锑等重金属对环境污染,大幅提升产品的环境友好度。
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