A method for preparing a high wear-resistant metal matrix composite material

Abstract

This invention relates to a method for preparing a high-wear-resistant metal-based composite material. This method significantly improves the wear resistance of the material by combining nano-reinforcing particles, surface modification technology, and self-healing capabilities. Aluminum alloy or titanium alloy is selected as the matrix, and nano-sized silicon carbide or alumina particles are used as reinforcing materials. The reinforcing materials are uniformly dispersed using processes such as stir casting, forging, diffusion bonding, infiltration, or powder metallurgy. The composite material structure is then precisely formed using 3D printing technology. The surface of the composite material is treated with a nano-coating or plasma treatment to enhance its wear resistance and corrosion resistance. Furthermore, by embedding microcapsules containing a repair agent into the material, automatic repair of worn areas is achieved, improving the material's reliability and service life. This composite material is particularly suitable for mechanical engineering and automotive manufacturing, especially in the manufacture of automotive brakes under high-wear environments, demonstrating excellent performance and broad application prospects.

Description

Technical Field

[0001] This invention relates to the field of materials science, specifically a method for preparing a highly wear-resistant metal matrix composite material. Background Technology

[0002] With the rapid development of modern industry, the requirements for material performance in mechanical engineering and automotive manufacturing are becoming increasingly stringent. In these fields, metal matrix composites have attracted much attention due to their excellent mechanical properties and good thermal stability. However, traditional metal matrix composites have shortcomings in wear resistance, which is particularly prominent in high-wear environments. In automotive brake applications, brake discs and brake drums are prone to surface wear due to friction during prolonged use, which not only affects brake performance but also shortens their service life.

[0003] To address this issue, researchers have attempted to enhance the wear resistance of composite materials by introducing hard particles or fibers to reinforce the metal matrix. These hard particles or fibers include silicon carbide (SiC), alumina (Al2O3), and carbon fibers, which can effectively improve the hardness and wear resistance of the material. However, these traditional reinforcing materials often suffer from uneven dispersion and weak bonding with the matrix, limiting further improvements in the composite material's performance.

[0004] Traditional manufacturing processes such as stir casting, forging, and diffusion bonding, while capable of bonding reinforcing materials to a metal matrix, often struggle to achieve precise molding of composite structures, especially when manufacturing parts with complex geometries. With the development of additive manufacturing technology, 3D printing has offered new possibilities for the preparation of metal matrix composites. Through 3D printing, the reinforcing material can be uniformly distributed within the metal matrix, thereby creating composite materials with excellent wear resistance.

[0005] Despite some progress, current high-wear-resistant metal matrix composites still have limitations, such as insufficient surface modification and a lack of self-healing capabilities. These issues restrict the performance of the materials in practical applications. Therefore, developing a novel preparation method to address these problems and improve the wear resistance and service life of composite materials is of significant research value and practical importance. Against this backdrop, this invention proposes a method for preparing high-wear-resistant metal matrix composites. By introducing nano-reinforcing particles, surface modification technology, and self-healing capabilities, this method aims to significantly enhance the wear resistance of the composite material, meeting the demands for high-performance materials in the fields of mechanical engineering and automotive manufacturing. Summary of the Invention

[0006] This invention provides a method for preparing a high-wear-resistant metal matrix composite material, aiming to significantly improve the wear resistance of the metal matrix composite material by introducing nano-reinforcing particles, surface modification technology, and self-healing function. The specific process of this method is as follows: Selection of Metal Matrix: In this invention, the selection of the metal matrix is ​​the first and crucial step in preparing high-wear-resistant metal-matrix composites. We selected aluminum alloys and titanium alloys as matrix materials, both widely recognized in industrial applications for their unique properties. Aluminum alloys, due to their lightweight nature and low density (approximately 2.7 g / cm³), significantly lower than many other metals, steel, and copper, offer a significant advantage in applications requiring weight reduction without sacrificing strength. Furthermore, aluminum alloys possess good thermal and electrical conductivity, excellent corrosion resistance, and ease of processing and forming, making them ideal for manufacturing various mechanical parts and structural components, particularly in the automotive, aerospace, and light industrial sectors. The melting point of aluminum alloys is generally between 550°C and 660°C, allowing them to be manufactured into different shapes and structures through various processing techniques, including casting, forging, rolling, and extrusion. Titanium alloys were chosen for their superior mechanical properties and corrosion resistance. Titanium alloys have a density of approximately 4.5 g / cm³, which, while heavier than aluminum alloys, results in exceptionally high strength, comparable to, and in some cases exceeding, that of high-strength steel. This characteristic makes titanium alloys an ideal material for manufacturing parts subjected to high loads and high temperatures, such as aero-engine components, missile structures, medical devices, and high-end sports equipment. Another significant feature of titanium alloys is their excellent corrosion resistance, primarily due to the dense oxide film that forms on their surface. This oxide film effectively blocks corrosive media, protecting the material itself from damage. Furthermore, titanium alloys retain their mechanical properties at high temperatures, making them particularly important in the manufacture of high-temperature components in the aerospace field. This invention selects aluminum and titanium alloys as the metal matrix, aiming to leverage their respective advantages and, through subsequent optimization of reinforcing materials and manufacturing processes, to produce a high-performance metal-based composite material with excellent wear resistance. This material will be particularly suitable for applications requiring extremely high strength and wear resistance, such as automotive brakes, high-speed train braking systems, and other high-wear mechanical components. By carefully selecting and applying these matrix materials, this invention will provide a novel composite material with significant performance advantages for industrial applications.

[0007] Selection of Reinforcing Materials: In this invention, selecting nanoscale silicon carbide (SiC) or alumina (Al2O3) particles as reinforcing materials is a crucial step, as they significantly impact the performance of the metal matrix composites. The particle size of the selected particles is strictly controlled to ensure uniform dispersion in the metal matrix and effective reinforcement. Silicon carbide particles are chosen due to their high melting point, high hardness, and good wear resistance. These properties allow SiC particles to act as a reinforcing phase in the composite, effectively improving the material's wear resistance and mechanical strength. Alumina particles are chosen for their excellent high-temperature resistance, wear resistance, and high strength, especially in high-temperature applications where they maintain their performance, providing additional strength and stability to the composite. To ensure optimal reinforcement, the nanoscale silicon carbide and alumina particles used in this invention have a particle size of less than 100 nanometers. This particle size range is selected based on the close relationship between the dispersibility of nanoparticles in the matrix and their reinforcing effect. Smaller particle size means a larger specific surface area, which contributes to the uniform dispersion of particles in the metal matrix, thereby improving the overall performance of the composite. Furthermore, the introduction of nanoscale particles can improve the fracture toughness of materials, enabling them to exhibit better crack resistance under impact or load. In the preparation process, nanoscale silicon carbide and alumina particles are obtained through chemical vapor deposition (CVD) or ball milling. CVD is a commonly used method for preparing nanoparticles, capable of producing high-purity nanoparticles at relatively low temperatures. Ball milling refines the raw material powder using a high-energy ball mill, thereby obtaining uniform nanoscale particles. These nanoparticles are then uniformly dispersed in an aluminum or titanium alloy matrix, and the reinforcing material is uniformly distributed within the metal matrix through powder metallurgy or 3D printing technology.

[0008] Dispersion of reinforcing materials: The reinforcing materials are uniformly dispersed in the metal matrix through processes such as stir casting, forging, diffusion bonding, infiltration, or powder metallurgy. Specifically, in the stir casting process, the metal matrix is ​​heated to a molten state, and nanoparticles are added to the molten metal. They are then uniformly dispersed by high-speed stirring, with a dispersion uniformity of over 99%.

[0009] Application of 3D Printing Technology: In this invention, 3D printing technology is used to stack materials layer by layer, achieving a uniform distribution of reinforcing materials within a metal matrix. During the printing process, the layer thickness is strictly controlled to ensure printing accuracy and material performance. Specifically, the layer thickness is set between 20 micrometers and 100 micrometers. This layer thickness range is selected based on the impact of layer thickness on the surface quality, mechanical properties, and printing time of the final part during 3D printing. Lower layer thicknesses typically result in smoother surfaces but also increase printing time and cost. Therefore, in this invention, precise control of layer thickness not only ensures the mechanical properties of the composite material but also optimizes printing efficiency and economy. 3D printing technology allows for the fabrication of composite material parts with complex geometries while ensuring a uniform distribution of reinforcing materials within the metal matrix, thus fully realizing the potential of nanoscale reinforcing materials.

[0010] Surface modification treatment: In this invention, surface modification treatment of the composite material is an important step in improving its wear resistance and corrosion resistance. Specifically, the surface of the composite material is treated with nano-coating or plasma treatment technology to enhance its performance. Coating materials can be selected from alumina, silicon carbide, diamond, or boron nitride, which are widely used in surface modification due to their excellent hardness and wear resistance.

[0011] The application of nano-coatings can significantly improve the surface hardness and wear resistance of materials while reducing the coefficient of friction, thereby extending the material's service life. In practice, the surface roughness is strictly controlled between Ra 0.8 and Ra 3.2 to ensure coating uniformity and adhesion. This roughness range not only helps improve the bonding strength between the coating and the substrate but also improves the material's lubrication properties to some extent, reducing wear. During the plasma treatment process, argon or nitrogen gas is used. By adjusting the treatment time and gas flow rate, the chemical and physical properties of the material surface can be effectively altered, further enhancing its corrosion resistance and wear resistance. This surface modification method can significantly improve the performance of composite materials in high-wear environments, ensuring their reliability and durability in practical applications.

[0012] Introduction of Self-Healing Function: In this invention, the self-healing function is introduced by embedding microcapsules into the composite material. These microcapsules contain a repairing agent that can be automatically released to repair worn areas when the material is damaged. The microcapsules can be prepared using emulsion polymerization, solvent evaporation, or interfacial polymerization, all of which ensure timely release of the repairing agent when the material is damaged. Emulsion polymerization is a commonly used method for microcapsule preparation. It involves dispersing the core material in an emulsion of the wall material, then spraying the emulsion into a dry, high-temperature medium using a spray device. This causes the solvent to evaporate rapidly, and the wall material precipitates out, forming microcapsules. This method is suitable for hydrophobic and heat-sensitive materials, has a short drying process, and avoids loss of bioactivity due to prolonged heating. Solvent evaporation involves dispersing the core material in a solvent and then spraying it onto the surface of a cooled wall material solution. Microcapsules are formed by controlling solvent evaporation. Microcapsules prepared by this method are prone to surface breakage and have a relatively low yield, but the wall material is moderately uniform, and the operation is simple, enabling large-scale production. Interfacial polymerization involves adding two monomers with different solubilities to the continuous phase of the wall material and the dispersed phase of the core material, respectively. An emulsifier is then added to each phase to form an emulsion. After mixing, when one solution is dispersed in the other, the two monomers migrate to the interface of the emulsion droplets and undergo monomer condensation reactions, forming microcapsule shells on the core material surface. This method is not only simple to operate but also offers high encapsulation efficiency, good density, and a fast reaction rate, making it suitable for encapsulating liquid core materials. Microcapsules prepared using this method can be uniformly dispersed in the composite material. When the composite material is worn, the repair agent released from the ruptured microcapsules can promptly repair the worn areas, thereby significantly improving the material's service life and reliability.

[0013] Heat Treatment: In this invention, the composite material is heat-treated to optimize its microstructure and properties, thereby improving its strength and toughness. The heat treatment process involves heating the composite material within a temperature range of 200°C to 600°C, ensuring a holding time of at least 2 hours. This heat treatment temperature range contributes to the stability of the material's internal structure, reduces internal stress, and promotes interfacial bonding between the silicon carbide (SiC) or alumina (Al2O3) reinforcing particles and the metal matrix. Appropriate heat treatment can significantly improve the mechanical properties of the composite material, especially its stability and durability at high temperatures. Furthermore, heat treatment helps eliminate internal stresses generated during the material's preparation process, reducing crack formation and thus improving the overall performance of the material. In this invention, the temperature and time of the heat treatment are precisely controlled to ensure that the composite material achieves optimal microstructure and properties.

[0014] Post-processing: In this invention, the post-processing steps of the composite material are a crucial step in ensuring that the final product meets application requirements. Specifically, post-processing includes machining, a process designed to shape the composite material into the desired form and size. To ensure machining accuracy and product quality, this invention employs high-precision machining equipment and strictly controls the machining accuracy within ±0.05 mm. This accuracy range not only meets the stringent dimensional accuracy requirements of most industrial applications but also ensures the assemblability and functionality of the composite material parts. During machining, burrs and unevenness on the material surface can be effectively removed by using precision cutting tools and advanced machining techniques, while maintaining the integrity of the material's internal structure. Furthermore, post-processing includes cleaning and inspecting the material surface to remove any possible machining residues, ensuring the surface quality and performance of the material. Through these meticulous post-processing steps, the final composite material product not only possesses excellent mechanical properties but also meets stringent dimensional and shape requirements, providing a reliable solution for various demanding industrial applications.

[0015] Material Properties: In this invention, the material properties of the composite material are carefully designed and optimized to meet specific application requirements. The thickness of the metal matrix is ​​carefully controlled within the range of 1 mm to 10 mm, a selection based on a comprehensive consideration of material weight, strength, and cost. A thinner matrix provides lighter weight, suitable for weight-sensitive applications, while a thicker matrix provides higher structural strength and wear resistance. Furthermore, the volume fraction of the reinforcing material is controlled between 5% and 30%, a range designed to ensure that the composite material fully utilizes the strengthening effect of the reinforcing material while maintaining the original good toughness of the metal matrix.

[0016] A low volume fraction of reinforcing material may not be sufficient to significantly improve the performance of composite materials, while a high volume fraction may lead to materials that are too brittle and hard, affecting their toughness. Therefore, by precisely controlling the volume fraction of reinforcing material, this invention successfully improves the strength and wear resistance of composite materials while maintaining their good toughness, making them suitable for a variety of demanding engineering applications.

[0017] The application of the composite material in automotive brakes, especially in the manufacture of brake discs or brake drums, and in the field of mechanical engineering, particularly in the manufacture of mechanical parts in high-wear environments, can significantly improve the wear resistance and service life of the parts.

[0018] Through the above steps, the preparation method of high wear-resistant metal matrix composite material provided by the present invention can effectively solve the shortcomings of traditional materials in terms of wear resistance and service life, and has broad application prospects and important economic value.

[0019] By adopting the above technical solution, the present invention can bring about the following specific technical effects: 1. Significantly Improved Wear Resistance: By introducing nano-sized silicon carbide (SiC) or alumina (Al2O3) particles as reinforcing materials and achieving uniform dispersion within a metal matrix, the composite material prepared in this invention exhibits excellent wear resistance. The nanoparticles, with a particle size of less than 100 nanometers, ensure more uniform dispersion within the matrix, thereby improving the material's hardness and wear resistance. Furthermore, the layer-by-layer stacking of materials using 3D printing technology further ensures the uniform distribution of the reinforcing material within the metal matrix, further enhancing the material's wear resistance.

[0020] 2. Enhanced Self-Healing Capability: By embedding microcapsules containing a repair agent into the composite material, this invention achieves the material's self-healing function. When wear occurs on the material surface, the microcapsules rupture to release the repair agent, automatically repairing the worn area and thus extending the material's service life. This self-healing function is particularly important for applications in high-wear environments, such as automotive brake components, significantly improving their reliability and durability.

[0021] 3. Improved Surface Properties: This invention applies a nano-coating or plasma treatment to the surface of the composite material. This not only enhances the material's wear resistance and corrosion resistance but also reduces surface roughness, thereby improving its surface properties. The surface roughness is controlled between Ra 0.8 and Ra 3.2, significantly improving the material's surface smoothness. This helps reduce friction and wear, further enhancing the material's wear resistance. Simultaneously, the excellent surface properties also contribute to improved aesthetics and cleanliness, making it more suitable for demanding applications. Attached Figure Description

[0022] Figure 1 The diagram shows the steps of the preparation method of the high wear-resistant metal matrix composite material of the present invention. Detailed Implementation

[0023] The following will refer to the appendices in the embodiments of the present invention. Figure 1 The technical solutions in the embodiments of the present invention are clearly and completely described herein. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0024] The preparation method and its effects of the present invention will be further described below through specific embodiments.

[0025] Example 1: Preparation of aluminum alloy matrix composite material 1. Substrate selection and preparation: Aluminum alloy is selected as the substrate material, with a thickness of 5 mm. It has good mechanical properties and is lightweight, making it suitable for manufacturing automotive brakes.

[0026] 2. Selection and treatment of reinforcing materials: Nanoscale silicon carbide (SiC) particles are selected as reinforcing materials, with their particle size controlled within 50 nanometers, in order to improve their dispersion uniformity in the aluminum alloy matrix.

[0027] 3. Material Dispersion: Nano-SiC particles are uniformly dispersed in an aluminum alloy matrix using powder metallurgy. High-speed stirring and ball milling processes ensure a dispersion uniformity of over 99%.

[0028] 4. 3D printing molding: Using 3D printing technology, aluminum alloy powder and SiC particle mixture are stacked layer by layer, with the layer thickness controlled at 50 micrometers, to manufacture composite material parts with complex geometries.

[0029] 5. Surface modification treatment: The printed composite material is treated with a nano-coating using an alumina coating, and the surface roughness is controlled at Ra 1.2 to enhance wear resistance and corrosion resistance.

[0030] 6. Self-healing function embedding: Microcapsules containing repair agents are embedded in the composite material. The microcapsules are prepared by emulsion polymerization to ensure that the repair agents can be released in time when the material is damaged.

[0031] 7. Heat treatment: The composite material is heat treated at 400°C for 2 hours to optimize its microstructure and properties.

[0032] 8. Post-processing: Machining is performed on the heat-treated composite material to ensure that the dimensional accuracy and surface quality meet the requirements of the brake components.

[0033] 9. Performance testing: The composite material prepared in Example 1 was subjected to performance testing. The results showed that its wear resistance was 3 times higher than that of traditional aluminum alloy, and its self-healing function showed good repair effect in simulated wear test.

[0034] Example 2: Preparation of titanium alloy matrix composite material 1. Substrate selection and preparation: Titanium alloy was selected as the substrate material, with a thickness of 3 mm. Due to its excellent strength and corrosion resistance, it is suitable for mechanical parts in high-wear environments.

[0035] 2. Selection and treatment of reinforcing materials: Nano-sized alumina (Al2O3) particles were selected as reinforcing materials, with their particle size controlled within 70 nanometers, in order to improve their dispersion uniformity in the titanium alloy matrix.

[0036] 3. Material Dispersion: Nano-Al2O3 particles are uniformly dispersed in the titanium alloy matrix using powder metallurgy. High-speed stirring and ball milling processes ensure a dispersion uniformity of over 99%.

[0037] 4. 3D printing molding: Using 3D printing technology, a mixture of titanium alloy powder and Al2O3 particles is stacked layer by layer, with the layer thickness controlled at 30 micrometers, to manufacture composite material parts with complex geometries.

[0038] 5. Surface modification treatment: The printed composite material is subjected to surface ionization treatment with boron nitride coating, and the surface roughness is controlled at Ra 0.8 to enhance wear resistance and corrosion resistance.

[0039] 6. Self-healing function embedding: Microcapsules containing repair agents are embedded in the composite material. The microcapsules are prepared by solvent evaporation to ensure that the repair agents can be released in time when the material is damaged.

[0040] 7. Heat treatment: The composite material is heat treated at 500°C for 3 hours to optimize its microstructure and properties.

[0041] 8. Post-processing: Machining is performed on the heat-treated composite material to ensure that the dimensional accuracy and surface quality meet the requirements of the mechanical parts.

[0042] 9. Performance testing: The composite material prepared in Example 2 was subjected to performance testing. The results showed that its wear resistance was 4 times higher than that of traditional titanium alloys, and its self-healing function showed good repair effect in simulated wear tests.

[0043] Through the above two embodiments, the preparation method of the high wear-resistant metal matrix composite material of the present invention has been verified. This method not only improves the wear resistance of the material but also introduces a self-healing function, significantly extending the service life of the material. It shows broad application prospects, especially in high-wear environments, such as automotive brakes and mechanical parts.

[0044] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing a high wear-resistant metal matrix composite material, characterized in that, Includes the following steps: s1. Choose aluminum alloy or titanium alloy as the metal matrix; s2. Select nanoscale silicon carbide or alumina particles as reinforcing materials, with a particle size of less than 100 nanometers; s3. The reinforcing material is uniformly dispersed in the metal matrix through stirring casting, forging, diffusion bonding, infiltration or powder metallurgy processes, with a dispersion uniformity of over 99%; s4. Using 3D printing technology, materials are stacked layer by layer to achieve uniform distribution of reinforcing materials in the metal matrix, with the layer thickness controlled between 20 micrometers and 100 micrometers; s5. Surface modification treatment of the composite material, including nano-coating or plasma treatment, to enhance wear resistance and corrosion resistance, with surface roughness controlled between Ra 0.8 and Ra 3.2; s6. Embedding microcapsules in composite materials, the microcapsules containing a repair agent for automatic repair of worn areas; s7. The composite material is subjected to heat treatment to optimize its microstructure and properties. The heat treatment temperature is controlled between 200°C and 600°C, and the holding time is not less than 2 hours. s8. The post-processing of the composite material includes machining to obtain the desired shape and size, with machining accuracy controlled within ±0.05 mm; s9. The thickness of the metal matrix ranges from 1 mm to 10 mm, and the volume fraction of the reinforcing material is controlled between 5% and 30%.

2. The preparation method according to claim 1, characterized in that, The nanoscale silicon carbide or alumina particles are prepared by chemical vapor deposition or ball milling.

3. The preparation method according to claim 1, characterized in that, The 3D printing technology uses metal powder as the material, and the thickness of the material layer is controlled between 20 micrometers and 100 micrometers during the printing process.

4. The preparation method according to claim 1, characterized in that, The nanocoating or plasma treatment includes coatings using materials such as alumina, silicon carbide, diamond, or boron nitride.

5. The preparation method according to claim 1, characterized in that, The microcapsules are prepared by methods including emulsion polymerization, solvent evaporation, or interfacial polymerization.

6. The preparation method according to claim 1, characterized in that, After preparation, the surface hardness of the composite material reaches HV 300 to HV 600.

7. The preparation method according to claim 1, characterized in that, After preparation, the composite material has a tensile strength of 300 MPa to 600 MPa.

8. The preparation method according to claim 1, characterized in that, After preparation, the composite material achieved a fracture toughness of 10 MPa·m. 0.5 Up to 20 MPa·m 0.5 .

9. The preparation method according to claim 1, characterized in that, The application of the composite material in automotive brakes, especially in the manufacture of brake discs or brake drums, can significantly improve the wear resistance and service life of the brakes.

Images