Carbon-ceramic-copper alloy powder metallurgical sintered friction material and method for producing the same

Abstract

The application relates to the technical field of friction materials, and particularly discloses a carbon-tao-copper alloy powder metallurgy sintering friction material and a preparation method thereof. The raw material of the friction material is mainly composed of the following components in volume percentage: 39.4-45.9% of a carbon component; 24.2-28.4% of a ceramic component; and 25.7-36.4% of a metal component. The carbon component is composed of graphite, carbon fiber powder and petroleum coke; the graphite is composed of natural flaky graphite and artificial granular graphite, the particle size specification of the artificial granular graphite is 30-50 mesh, 50-100 mesh and 100-200 mesh; the ceramic component is composed of zirconite sand, alumina, quartz powder, zirconium dioxide, silicon carbide and potassium feldspar powder; and the metal component is composed of copper powder, tin powder, zinc powder, nickel powder and iron powder. In the application, the proportion of the carbon and ceramic components is increased, and the proportion of the metal component is reduced; the specific operation of limiting material mixing, green compact pressing and sintering forming and the like processes is adopted, so that the friction material is light in weight, the friction coefficient is more stable, the dynamic and static friction coefficients are close to each other, the friction material can withstand high energy and thermal load, and the wear-resistant service life is long.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of metal friction materials, more particularly, it relates to carbon-ceramic-copper alloy powder metallurgy sintered friction material and a preparation method thereof. BACKGROUND

[0002] Friction materials include metal friction materials, non-metal friction materials, composite friction materials, and coated friction materials, which are widely used in the fields of clutches and brakes of engineering machinery, agricultural machinery, mining machinery, ships and automobiles, high-speed trains, forging and pressing machines, general machinery, machine tools and electrical appliances, speed regulating clutches, etc.

[0003] However, as machinery and equipment develop towards large power, heavy load, and structural miniaturization, friction materials are required to have higher friction coefficients, higher temperature and heat resistance, greater energy and power load allowance values, higher pressure resistance, strong overload resistance, better durability, and longer service life. SUMMARY

[0004] In order to optimize the friction coefficient and high temperature and pressure resistance of the friction material, the present application provides a carbon-ceramic-copper alloy powder metallurgy sintered friction material and a preparation method thereof.

[0005] In a first aspect, the present application provides a carbon-ceramic-copper alloy powder metallurgy sintered friction material, and the specific technical solutions are as follows: the carbon-ceramic-copper alloy powder metallurgy sintered friction material is mainly composed of the following components in volume percentage:

[0006] The raw material is mainly composed of the following components in volume percentage:

[0007] The carbon component is 39.4-45.9%;

[0008] The ceramic component is 24.2-28.4%;

[0009] The metal component is 25.7-36.4%;

[0010] The carbon component is composed of graphite, carbon fiber powder, and petroleum coke; the graphite is composed of natural flaky graphite and artificial granular graphite, the particle size specification of the artificial granular graphite is 30-50 mesh, 50-100 mesh, and 100-200 mesh;

[0011] The ceramic component is composed of zirconite sand, aluminum oxide, quartz powder, zirconium dioxide, silicon carbide, and potassium feldspar powder;

[0012] The metal component is composed of copper powder, tin powder, zinc powder, nickel powder, and iron powder.

[0013] By adopting the technical scheme, the specific components and corresponding adding amounts of the metal component, the carbon component and the ceramic component are limited, so that the obtained friction material has a high friction coefficient, good high-temperature resistance and high-pressure resistance, and is not easy to wear during use, thereby prolonging the service life.

[0014] Further preferably, in the ceramic component, the volume percentage of

[0015] Zircon sand 8.2-9.8%;

[0016] Alumina 2.4-2.8%;

[0017] Quartz powder 3.1-3.6%;

[0018] Zirconium dioxide 5.2-6.1%;

[0019] Silicon carbide 3.1-3.6%;

[0020] Potassium feldspar powder 2.2-2.5%.

[0021] By adopting the technical scheme, the ceramic component is composed of zirconium silicate zircon sand, alumina, quartz powder silicon dioxide, zirconium dioxide, silicon carbide and potassium feldspar powder with specific volume percentages, which cooperates with the metal component and the carbon component, thereby increasing the lubrication effect and reducing the wear loss.

[0022] Further preferably, in the metal component, the volume percentage of

[0023] Copper 18.3-25.8%;

[0024] Tin 2-2.8%;

[0025] Zinc 1.5-2.2%;

[0026] Nickel 1.1-1.6%;

[0027] Iron 2.8-4.0%.

[0028] Further preferably, in the carbon component, the volume percentage of

[0029] Natural flake graphite 2.1-2.5%;

[0030] 30-50 mesh artificial granular graphite 19.2-22.3%;

[0031] 50-100 mesh artificial granular graphite 4.3-5%;

[0032] 100-200 mesh artificial granular graphite 3.2-3.7%;

[0033] Carbon fiber powder 5.3-6.2%;

[0034] Calcined petroleum coke 5.3-6.2%.

[0035] The technical scheme has the advantages that the specific components in the metal component and the carbon component have better lubricating effect, and the carbon component formed by different materials can cooperate with other components to make the material have the characteristics of small friction coefficient fluctuation value, good friction coefficient stability, moderate wear amount, and good comprehensive friction and wear performance.

[0036] In a second aspect, the application provides a preparation method of a carbon-ceramic-copper alloy powder metallurgy sintered friction material, and the specific technical scheme is as follows:

[0037] Step one, preliminary partial mixing: the copper powder in the metal component is fragmented and fully mixed with the molding component completely volatilized during sintering to obtain a mixed initial material with a particle size not less than 600 mesh;

[0038] Step two, re-mixing: the mixed initial material, the ceramic component, and the remaining metal component are mixed for 1-2 hours, then the carbon component is added and mixed for 20-25 minutes to obtain a mixed raw material;

[0039] Step three, pressing green body: the mixed raw material is pressed at 90-95°C and 8-90MPa to obtain a thin sheet green body;

[0040] Step four, sintering and cooling: the thin sheet green body is sintered in three stages under gas protection, the temperature of the three-stage sintering gradually increases from 350°C to 910°C, the time of the three-stage sintering is 230-240 minutes, and the pressure of the three-stage sintering is 2.8-3.1MPa; cooling to obtain a carbon-ceramic sintered metal friction material;

[0041] The molding component in step one is rosin powder and white oil, the rosin powder accounts for 1.8% of the total volume of the raw material, and the white oil accounts for 1.55% of the total volume of the raw material.

[0042] In the application, the carbon component and the ceramic component account for a higher volume ratio in the raw material, and the copper is fragmented into ultra-fine powder not less than 600 mesh, so that it can be effectively dispersed in the gaps between the carbon component and the ceramic component, and even coat the surfaces of the carbon component and the ceramic component.

[0043] During the preliminary partial mixing, the rosin powder in the molding component is fragmented and mixed with the copper powder in the metal component, which can improve the adhesion between different components during pressing, effectively clean the surface of the friction material during sintering, improve the strength of the sintering neck, and thus improve the strength of the friction material; at the same time, the white oil in the molding component is also added together with the rosin powder during the fragmentation and mixing process, which is to reduce the friction between the powder particles during pressing and improve the flowability of the powder during pressing to make the green body dense.

[0044] In the mixing process, the powder particles in each component produce dynamic friction between each other, because of the friction, the carbon component will be transferred to the particle surface of the metal component and the ceramic component, which will make the surface dirty, and will reduce the binding force between the components after sintering, so the mixing time should be controlled within 20-25min to reduce the possibility of the graphite particles in the carbon component dirtying the surface of other particles.

[0045] In the process of pressing the green body, the rosin powder in the forming component softens under heat, the mixed raw materials flow and the internal gas is discharged as the pressure increases from small to large, so that the inside of the flake green body is more dense and compact.

[0046] In step four, three-stage sintering is adopted, and in the sintering process, the temperature gradually increases, and within the appropriate sintering time range, the processes of forming agent discharge, powder particle surface purification, alloy component diffusion metal component alloying, and material densification are completed at different temperature stages, so that the obtained carbon-ceramic sintered metal friction material has excellent overall performance.

[0047] Further, the forming agent in step one is rosin powder and white oil, the rosin powder is 1.8% of the total volume of the raw materials, and the white oil is 1.55% of the total volume of the raw materials; in the pressing process of step three, first pre-pressing under a pressure of 8-9MPa for 12-15s, and then pressing under a pressure of 90-95MPa for 2-3s.

[0048] In the above technical solution, in step one, an appropriate amount of rosin powder and white oil are used as forming agents, which is beneficial to contact all raw materials, thereby facilitating the pressing of the green body to be more compact. On the other hand, in step three, a lower pressure is first used to discharge gas, and when the pressure is low, the copper powder moves slightly, so that the graphite particles are not easily damaged by excessive extrusion.

[0049] Further preferably, in step four, the gas is hydrogen-nitrogen protective gas, which is composed of 8-25% hydrogen gas and the balance of nitrogen gas.

[0050] The use of the above technical solution is beneficial to the good gas protection effect of the flake green body during sintering.

[0051] Further preferably, the three-stage sintering in step four includes: first-stage sintering at a sintering temperature of 350℃ for 20-30min; second-stage sintering at a sintering temperature of 650℃ for 60-70min; and third-stage sintering at a sintering temperature of 910℃ for 140-150min.

[0052] By adopting the technical scheme, the carbon-ceramic sintered metal friction material obtained is relatively more beneficial to reduce the wear rate, thereby prolonging the service life.

[0053] Further preferably, in the fourth step, during the temperature rising process of the third stage sintering, a pressurizing treatment is performed, and the pressure is 2.8-3.1 MPa; during the cooling process of the fourth step, the pressure is removed after cooling to below 550 DEG C.

[0054] By adopting the technical scheme, the pressure is continuously maintained, which is beneficial to the compactness of the obtained metal friction material.

[0055] Before the fourth step starts sintering, a bonding layer powder is scattered on the steel back of the pre-sintering equipment, and a bonding layer is formed on the adhered steel back plane after pre-sintering; the bonding layer powder is composed of the following components in mass percentage: 200 mesh copper powder 86.5%;

[0056] tin powder 12%;

[0057] zinc powder 1.5%;

[0058] The use amount of the bonding layer powder is 3-4 g / dm 2 , the pre-sintering temperature is 800 DEG C, and the mesh belt furnace sintering time is 15 min;

[0059] In the fourth step, the sheet green body is placed on the bonding layer for three-stage sintering treatment.

[0060] By adopting the technical scheme, the friction material is more firmly bonded with the pre-sintering equipment, thereby making the sintering process more uniform.

[0061] In summary, the present application has the following beneficial effects:

[0062] In the present application, by specifically matching the volume ratio of the carbon component, the ceramic component and the metal component, the proportion of the carbon component and the ceramic component is high, which is beneficial to reducing the specific gravity and the cost, and the obtained friction material has the advantages of light weight, low production cost and saving of non-ferrous metal materials; further, the volume ratio and the particle size of the specific components in the carbon component, the ceramic component and the metal component are limited, thereby making the friction coefficient of the obtained friction material more stable, the wear rate is reduced, and the service life is prolonged.

[0063] In the present application, artificial granular graphite with different particle size ranges is used for mutual compatibility, thereby greatly improving the lubricating effect, making the addition of raw materials more uniform, and making the final product friction material have a good surface smoothness.

[0064] In the process of preparing the friction material, the copper powder and the forming agent are first crushed and mixed, which is beneficial to the better contact and compatibility of the crushed copper powder with the ceramic components, carbon components and other metal components, and thus the obtained finished friction material has better overall performance, such as improving the overall friction coefficient of the friction material and reducing the overall wear rate. BRIEF DESCRIPTION OF DRAWINGS

[0065] Figure 1 is a microscope picture of the sample prepared in Example 4 in the present application under microscope magnification of 50 times;

[0066] Figure 2 is a microscope picture of the sample prepared in Example 5 in the present application under microscope magnification of 50 times. DETAILED DESCRIPTION

[0067] EMBODIMENT

[0068] Example 1: Carbon-Tao-Copper Alloy Powder Metallurgy Sintered Friction Material, in which the following raw materials are used in volume percentage:

[0069] Metal components:

[0070] Copper powder (100 mesh) 25.8%, tin powder (200 mesh) 2.8%, zinc powder (300 mesh) 2.2%, nickel powder (300 mesh) 1.6%, iron powder (100 mesh) 4.0%;

[0071] Carbon components:

[0072] Natural flake graphite (model 199) 2.1%, artificial granular graphite (30-50 mesh) 19.2%, artificial granular graphite (50-100 mesh) 4.3%, artificial granular graphite (100-200 mesh) 3.2%, carbon fiber powder (50-120 mesh) 5.3%, calcined petroleum coke (60-100 mesh) 5.3%;

[0073] Ceramic components:

[0074] Zircon sand (100-200 mesh) 8.2%, alumina (325 mesh) 2.4%, quartz powder (200-325 mesh) 3.1%, zirconium dioxide (200-325 mesh) 5.2%, silicon carbide (400 mesh) 3.1%, potassium feldspar powder (80-120 mesh) 2.2%.

[0075] And the preparation method of the carbon-tao ceramic sintered metal friction material is as follows:

[0076] Step one, mixing: put the copper powder in the metal component and the molding component (rosin powder, 100 mesh, 1.8% of the total volume of raw materials; white oil, 1.55% of the total volume of raw materials) which is completely volatilized during sintering into a high-speed knife-type pulverizer, and pulverize into ultra-fine powder of not more than 600 mesh at 10,000 rpm to complete the mixing, and obtain the mixed primary material;

[0077] Step two, mixing again: mix the mixed primary material, ceramic component, and the remaining metal component for 2 hours, then add the carbon component and continue mixing for 25 minutes to obtain the mixed raw material;

[0078] Step three, pressing green body: pre-press the mixed raw material at 95°C and 8MPa for 15s, and then press at 90MPa for 3s to obtain the thin sheet green body;

[0079] And sprinkle the adhesive layer powder on the steel back of the pre-sintering equipment, and form an adhesive layer on the adhered steel back plane after pre-sintering; the adhesive layer powder is composed of the following components in mass percentage: 200 mesh copper powder 86.5%;

[0080] Tin powder 12%;

[0081] Zinc powder 1.5%;

[0082] The use amount of the adhesive layer powder is 3g / dm 2 , the pre-sintering temperature is 800°C, and the mesh belt furnace sintering time is 15min. Then place the thin sheet green body obtained in step three on the adhesive layer.

[0083] Step four, sintering and cooling: under gas protection, the thin sheet green body is subjected to three-stage sintering, the sintering temperature gradually increases from 350°C to 910°C, the sintering time is 230-240min, and the pressure during the third-stage sintering is 3.1MPa; cooling to obtain the carbon-ceramic sintered metal friction material;

[0084] In step four, the specific parameters of the three-stage sintering of the thin sheet green body are as follows:

[0085] First-stage sintering, sintering temperature is 350°C, sintering time is 20min;

[0086] Second-stage sintering, the sintering temperature is increased to 650°C, and the sintering time is 60min;

[0087] Third-stage sintering, the sintering temperature is increased to 910°C, and during the temperature increasing process, the pressure is kept at 3.1MPa, and the sintering time is 150min.

[0088] After sintering, the pressure is removed after cooling to below 550°C to obtain the carbon-ceramic sintered metal friction material.

[0089] Example 2: Carbon-Ceramic-Copper alloy powder metallurgical sintered friction material, differing from Example 1 in that the specific composition is different in volume percent:

[0090] Metallic components:

[0091] Copper powder (100 mesh) 24.4%, tin powder (200 mesh) 2.6%, zinc powder (300 mesh) 2.1%, nickel powder (300 mesh) 1.5%, iron powder (100 mesh) 3.7%;

[0092] Carbon components:

[0093] Natural flake graphite (type 199) 2.2%, artificial granular graphite (30-50 mesh) 19.8%, artificial granular graphite (50-100 mesh) 4.4%, artificial granular graphite (100-200 mesh) 3.3%; carbon fiber powder (50-120 mesh) 5.5%, calcined petroleum coke (60-100 mesh) 5.5%;

[0094] Ceramic components:

[0095] Zircon sand (100-200 mesh) 8.5%, alumina (325 mesh) 2.5%, quartz powder (200-325 mesh) 3.2%, zirconium dioxide (200-325 mesh) 5.4%, silicon carbide (400 mesh) 3.2%, potassium feldspar powder (80-120 mesh) 2.2%.

[0096] Example 2-A: Carbon-Ceramic-Copper alloy powder metallurgical sintered friction material, differing from Example 1 in that the specific composition is different in volume percent:

[0097] Metallic components:

[0098] Copper powder (100 mesh) 24.4%, tin powder (200 mesh) 2.6%, zinc powder (300 mesh) 2.1%, nickel powder (300 mesh) 1.5%, iron powder (100 mesh) 3.7%;s

[0099] Carbon components:

[0100] Natural flake graphite (type 199) 2.1%, artificial granular graphite (30-50 mesh) 19.2%, artificial granular graphite (50-100 mesh) 4.3%, artificial granular graphite (100-200 mesh) 3.2%; carbon fiber powder (50-120 mesh) 5.3%, calcined petroleum coke (60-100 mesh) 5.3%;

[0101] Ceramic components:

[0102] Zircon sand (100-200 mesh) 8.9%, alumina (325 mesh) 2.6%, quartz powder (200-325 mesh) 3.4%, zirconia (200-325 mesh) 5.7%, silicon carbide (400 mesh) 3.4%, potassium feldspar powder (80-120 mesh) 2.3%.

[0103] Example 3: Carbon-Ceramic-Copper alloy powder metallurgical sintered friction material, differing from Example 1 in that the volume percentages of the specific components are different:

[0104] Metallic components:

[0105] Copper powder (100 mesh) 23.1%, tin powder (200 mesh) 2.5%, zinc powder (300 mesh) 1.9%, nickel powder (300 mesh) 1.4%, iron powder (100 mesh) 3.5%;

[0106] Carbon components:

[0107] Natural flake graphite (type 199) 2.3%, artificial granular graphite (30-50 mesh) 20.3%, artificial granular graphite (50-100 mesh) 4.5%, artificial granular graphite (100-200 mesh) 3.4%; carbon fiber powder (50-120 mesh) 5.6%, calcined petroleum coke (60-100 mesh) 5.6%;

[0108] Ceramic components:

[0109] Zircon sand (100-200 mesh) 8.7%, alumina (325 mesh) 2.6%, quartz powder (200-325 mesh) 3.3%, zirconia (200-325 mesh) 5.5%, silicon carbide (400 mesh) 3.4%, potassium feldspar powder (80-120 mesh) 2.4%.

[0110] Example 4: Carbon-Ceramic-Copper alloy powder metallurgical sintered friction material, differing from Example 1 in that the volume percentages of the specific components are different:

[0111] Metallic components:

[0112] Copper powder (100 mesh) 21.8%, tin powder (200 mesh) 2.3%, zinc powder (300 mesh) 1.8%, nickel powder (300 mesh) 1.3%, iron powder (100 mesh) 3.3%;

[0113] Carbon components:

[0114] Natural flake graphite (type 199) 2.3%, artificial granular graphite (30-50 mesh) 20.9%, artificial granular graphite (50-100 mesh) 4.6%, artificial granular graphite (100-200 mesh) 3.5%; carbon fiber powder (50-120 mesh) 5.8%, calcined petroleum coke (60-100 mesh) 5.8%;

[0115] Ceramic Component:

[0116] Zircon sand (100-200 mesh) 9%, alumina (325 mesh) 2.6%, quartz powder (200-325 mesh) 3.4%, zirconia (200-325 mesh) 5.7%, silicon carbide (400 mesh) 3.4%, potassium feldspar powder (80-120 mesh) 2.5%.

[0117] The micrograph of the metal friction material sample prepared in Example 4 at 50X magnification under a microscope is shown in Fig. 4. Figure 1

[0118] Example 5: Carbon-Ceramic-Copper alloy powder metallurgical sintered friction material, the difference from Example 1 is that the volume percentage of the specific components is different:

[0119] Metal Component:

[0120] Copper powder (100 mesh) 20.6%, tin powder (200 mesh) 2.2%, zinc powder (300 mesh) 1.7%, nickel powder (300 mesh) 1.3%, iron powder (100 mesh) 3.1%;

[0121] Carbon Component:

[0122] Natural flake graphite (model 199) 2.4%, artificial granular graphite (30-50 mesh) 21.4%, artificial granular graphite (50-100 mesh) 4.8%, artificial granular graphite (100-200 mesh) 3.6%, carbon fiber powder (50-120 mesh) 5.9%, calcined petroleum coke (60-100 mesh) 5.9%;

[0123] Ceramic Component:

[0124] Zircon sand (100-200 mesh) 9.2%, alumina (325 mesh) 2.7%, quartz powder (200-325 mesh) 3.5%, zirconia (200-325 mesh) 5.8%, silicon carbide (400 mesh) 3.5%, potassium feldspar powder (80-120 mesh) 2.4%.

[0125] The micrograph of the metal friction material sample prepared in Example 5 at 50X magnification under a microscope is shown in Fig. 5. Figure 2

[0126] Example 6: Carbon-Ceramic-Copper alloy powder metallurgical sintered friction material, the difference from Example 1 is that the volume percentage of the specific components is different:

[0127] Metal Component:

[0128] ​​Copper powder (100 mesh) 19.4%, tin powder (200 mesh) 2.1%, zinc powder (300 mesh) 1.6%, nickel powder (300 mesh) 1.2%, iron powder (100 mesh) 3.0%;

[0129] Carbon component:

[0130] Natural flake graphite (type 199) 2.4%, artificial particulate graphite (30-50 mesh) 21.9%, artificial particulate graphite (50-100 mesh) 4.9%, artificial particulate graphite (100-200 mesh) 3.6%; carbon fiber powder (50-120 mesh) 6.1%, calcined petroleum coke (60-100 mesh) 6.1%;

[0131] Ceramic component:

[0132] Zircon sand (100-200 mesh) 9.3%, alumina (325 mesh) 2.8%, quartz powder (200-325 mesh) 3.6%, zirconia (200-325 mesh) 5.9%, silicon carbide (400 mesh) 3.6%, potassium feldspar powder (80-120 mesh) 2.5%.

[0133] Example 6-A: Carbon-Ceramic-Copper alloy powder metallurgical sintered friction material, differing from Example 6 in that the volume percentages of the specific components are different:

[0134] Metal component:

[0135] Copper powder (100 mesh) 19.4%, tin powder (200 mesh) 2.1%, zinc powder (300 mesh) 1.6%, nickel powder (300 mesh) 1.2%, iron powder (100 mesh) 3.0%;

[0136] Carbon component:

[0137] Natural flake graphite (type 199) 2.4%, artificial particulate graphite (30-50 mesh) 21.8%, artificial particulate graphite (50-100 mesh) 4.7%, artificial particulate graphite (100-200 mesh) 3.5%; carbon fiber powder (50-120 mesh) 6.0%, calcined petroleum coke (60-100 mesh) 5.9%;

[0138] Ceramic component:

[0139] Zircon sand (100-200 mesh) 9.8%, alumina (325 mesh) 2.8%, quartz powder (200-325 mesh) 3.6%, zirconia (200-325 mesh) 6.1%, silicon carbide (400 mesh) 3.6%, potassium feldspar powder (80-120 mesh) 2.5%.

[0140] Example 7: Carbon-Ceramic-Copper alloy powder metallurgical sintered friction material, differing from Example 1 in that the volume percentages of the specific components are different:

[0141] Metallic components:

[0142] Copper powder (100 mesh) 18.3%, tin powder (200 mesh) 2.0%, zinc powder (300 mesh) 1.5%, nickel powder (300 mesh) 1.1%, iron powder (100 mesh) 2.8%;

[0143] Carbon components:

[0144] Natural flake graphite (type 199) 2.5%, artificial granular graphite (30-50 mesh) 22.3%, artificial granular graphite (50-100 mesh) 5.0%, artificial granular graphite (100-200 mesh) 3.7%; carbon fiber powder (50-120 mesh) 6.2%, calcined petroleum coke (60-100 mesh) 6.2%;

[0145] Ceramic components:

[0146] Zircon sand (100-200 mesh) 9.8%, alumina (325 mesh) 2.8%, quartz powder (200-325 mesh) 3.6%, zirconium dioxide (200-325 mesh) 6.1%, silicon carbide (400 mesh) 3.6%, potassium feldspar powder (80-120 mesh) 2.5%.

[0147] Comparative Example

[0148] Comparative Example 1: A metallic friction material, which differs from Example 1 in that the specific components and corresponding volume percentages are different:

[0149] Metallic components (38.4%):

[0150] Copper powder (100 mesh) 27.3%, tin powder (200 mesh) 2.9%, zinc powder (300 mesh) 2.3%, nickel powder (300 mesh) 1.7%, iron powder (100 mesh) 4.2%;

[0151] Carbon components (38.0%):

[0152] Natural flake graphite (type 199) 2.1%, artificial granular graphite (30-50 mesh) 18.5%, artificial granular graphite (50-100 mesh) 4.1%, artificial granular graphite (100-200 mesh) 3.1%; carbon fiber powder (50-120 mesh) 5.1%, calcined petroleum coke (60-100 mesh) 5.1%;

[0153] Ceramic components (23.6%):

[0154] Zircon sand (100-200 mesh) 8.2%, alumina (325 mesh) 2.3%, quartz powder (200-325 mesh) 3.0%, zirconia (200-325 mesh) 5.0%, silicon carbide (400 mesh) 3.0%, potassium feldspar powder (80-120 mesh) 2.1%.

[0155] Comparative Example 2: A metal friction material, which differs from Example 1 in that the specific composition and corresponding volume percentages are different:

[0156] Metallic components (36.4%):

[0157] Copper powder (100 mesh) 25.8%, tin powder (200 mesh) 2.8%, zinc powder (300 mesh) 2.2%, nickel powder (300 mesh) 1.6%, iron powder (100 mesh) 4.0%;

[0158] Carbon components (37.4%):

[0159] Natural flake graphite (type 199) 2.0%, artificial granular graphite (30-50 mesh) 18.2%, artificial granular graphite (50-100 mesh) 4.0%, artificial granular graphite (100-200 mesh) 3.0%; carbon fiber powder (50-120 mesh) 5.1%, calcined petroleum coke (60-100 mesh) 5.1%;

[0160] Ceramic components (26.2%):

[0161] Zircon sand (100-200 mesh) 9.0%, alumina (325 mesh) 2.6%, quartz powder (200-325 mesh) 3.3%, zirconia (200-325 mesh) 5.7%, silicon carbide (400 mesh) 3.3%, potassium feldspar powder (80-120 mesh) 2.3%.

[0162] Comparative Example 3: A metal friction material, which differs from Example 7 in that the specific composition and corresponding volume percentages are different:

[0163] Metallic components (23.5%):

[0164] Copper powder (100 mesh) 16.7%, tin powder (200 mesh) 1.8%, zinc powder (300 mesh) 1.4%, nickel powder (300 mesh) 1.0%, iron powder (100 mesh) 2.6%;

[0165] Carbon components (47.2%):

[0166] Natural flake graphite (type 199) 2.6%, artificial particulate graphite (30-50 mesh) 22.9%, artificial particulate graphite (50-100 mesh) 5.1%, artificial particulate graphite (100-200 mesh) 3.8%; carbon fiber powder (50-120 mesh) 6.4%, calcined petroleum coke (60-100 mesh) 6.4%;

[0167] Ceramic component (29.3%):

[0168] Zircon sand (100-200 mesh) 9.9%, alumina (325 mesh) 2.9%, quartz powder (200-325 mesh) 3.8%, zirconium dioxide (200-325 mesh) 6.3%, silicon carbide (400 mesh) 3.8%, potassium feldspar powder (80-120 mesh) 2.6%.

[0169] Comparative Example 4: A metal friction material, which differs from Example 7 in that the specific components and corresponding volume percentages are different:

[0170] Metal component (25.7%):

[0171] Copper powder (100 mesh) 18.3%, tin powder (200 mesh) 2.0%, zinc powder (300 mesh) 1.5%, nickel powder (300 mesh) 1.1%, iron powder (100 mesh) 2.8%;

[0172] Carbon component (47.9%):

[0173] Natural flake graphite (type 199) 2.6%, artificial particulate graphite (30-50 mesh) 23.2%, artificial particulate graphite (50-100 mesh) 5.2%, artificial particulate graphite (100-200 mesh) 3.9%; carbon fiber powder (50-120 mesh) 6.5%, calcined petroleum coke (60-100 mesh) 6.5%;

[0174] Ceramic component (26.4%):

[0175] Zircon sand (100-200 mesh) 8.9%, alumina (325 mesh) 2.7%, quartz powder (200-325 mesh) 3.4%, zirconium dioxide (200-325 mesh) 5.6%, silicon carbide (400 mesh) 3.4%, potassium feldspar powder (80-120 mesh) 2.4%.

[0176] Comparative Example 5: A metal friction material, which differs from Example 7 in that the specific components and corresponding volume percentages are different:

[0177] Metal component (22.1%):

[0178] Copper powder (100 mesh) 15.7%, tin powder (200 mesh) 1.7%, zinc powder (300 mesh) 1.3%, nickel powder (300 mesh) 1.0%, iron powder (100 mesh) 2.4%;

[0179] Carbon component (48.1%):

[0180] Natural flake graphite (type 199) 2.6%, artificial granular graphite (30-50 mesh) 23.4%, artificial granular graphite (50-100 mesh) 5.2%, artificial granular graphite (100-200 mesh) 3.9%, carbon fiber powder (50-120 mesh) 6.5%, calcined petroleum coke (60-100 mesh) 6.5%;

[0181] Ceramic component (29.8%):

[0182] Zircon sand (100-200 mesh) 10.1%, alumina (325 mesh) 3.0%, quartz powder (200-325 mesh) 3.8%, zirconium dioxide (200-325 mesh) 6.4%, silicon carbide (400 mesh) 3.8%, potassium feldspar powder (80-120 mesh) 2.7%.

[0183] Comparative Example 6: A metal friction material, which differs from Example 1 in that the sintering process in step four is sintered at 650°C for 230 min.

[0184] Comparative Example 7: A metal friction material, which differs from Example 1 in that the sintering process in step four is sintered at 910°C for 230 min.

[0185] Comparative Example 8: A metal friction material, which differs from Example 1 in that the sintering process in step four is sintered at 350°C for 20 min and then sintered at 910°C for 210 min.

[0186] Comparative Example 9: A metal friction material, which differs from Example 1 in that the sintering process in step four is sintered at 650°C for 60 min and then sintered at 910°C for 170 min.

[0187] Example 8: Carbon-ceramic-copper alloy powder metallurgy sintered friction material, which differs from Example 7 in that in the pressing process in step three: the mixed raw materials are pre-pressed at 90°C and 9 MPa for 12 s, and then pressed at 95 MPa for 2 s to obtain a thin green body.

[0188] Example 9: Carbon-ceramic-copper alloy powder metallurgy sintered friction material, which differs from Example 7 in that in step four of the preparation process, the sintering temperature is different, as follows:

[0189] First sintering, sintering temperature is 350℃, sintering time is 30min;

[0190] Second sintering, sintering temperature is 650℃, sintering time is 70min;

[0191] Third sintering, sintering temperature is 910℃, and in the process of heating, pressure is kept at 2.8MPa, sintering time is 140min;

[0192] After sintering, cooling to below 550℃, then remove pressure, obtain carbon-ceramic sintered metal friction material.

[0193] Test process:

[0194] Test one: according to GB / T 10421-2002 Determination of density of sintered metal friction material, respectively detect the density of the obtained sintered product of each example and comparative example, and record the obtained data in Table 1.

[0195] Test two: according to the requirements of JB / T 7269-2007 and HB 5434.7-2004, respectively detect the average dynamic friction coefficient, static friction coefficient, friction stability coefficient, friction material wear rate and wear rate of the counter steel disc of the obtained product of each example and comparative example, the specific test conditions are as follows:

[0196] Sample friction layer size Φ75×Φ53, rotation speed 6000r / min, pressure 0.68MPa, inertia 0.38Kg·m 2 , 1000 times braking test counter part material: 42CrMo, heat treatment HRC30-35.

[0197] Finally, record the obtained data in Table 1.

[0198] Test three: according to the requirements of SAE J2487-2000 SAE No.2Friction Test Machine 3600r / min Stepped Power Test and JB / T 7909-2011, respectively detect the maximum energy density and energy load allowable value of the obtained product of each example and comparative example, the specific test conditions are as follows:

[0199] Sample friction layer size Φ75×Φ53, rotation speed 3600r / min, pressure 0.68MPa, braking frequency 1 time / minute, initial stage inertia 0.3Kg·m 2 , and 0.01Kg·m 2The inertia increment of the friction pair is increased step by step. 25 braking tests are carried out at each inertia level until the failure of the friction pair. The energy density of the level before the failure level is the maximum energy density, and the product of the energy density of the level before the failure level and the maximum power density is the energy load allowance value. The counterpart material is 42CrMo, and the heat treatment is HRC 30-35.

[0200] Finally, the obtained data are recorded in Table 1.

[0201] Test four: according to the requirements in JB / T9141.3-2013 Flexible Graphite Sheet Part 3: Compression Strength Test Method, the maximum static pressure test is carried out on the finished products obtained in each example and comparative example, and the obtained data are recorded in Table 1.

[0202] Test five: according to the requirements in GB / T 7124-2008, the bonding surface shear strength test is carried out on the finished products obtained in each example and comparative example, and the obtained data are recorded in Table 1.

[0203] Table 1: Test results of the finished product samples obtained in each example and comparative example

[0204]

[0205] It can be known from Table 1 that the finished product obtained by using the formula and method in the application can have good average dynamic friction coefficient, static friction coefficient and friction stability coefficient, and the friction material wear rate and the wear rate of the counter steel disc are kept at a low level, while the maximum energy density, energy load allowance value, maximum static pressure and bonding surface shear strength are all high. It can be known that the finished product obtained in the above examples is not easy to be worn in use and has a long service life.

[0206] Compared with the comparative sample 1-2 obtained in comparative examples 1-2, the maximum energy density and energy load allowance value of the comparative sample 1-2 are lower than those in the examples, and the reason for causing this result may be that: the volume ratio content of the carbon component in the comparative sample 1 is low and the volume ratio of the metal component is high; and the volume ratio of each component in the carbon component in the comparative sample 2 is low.

[0207] The friction material wear rate of the comparative sample 3-4 obtained in comparative examples 3-4 is higher than that in the examples, which indicates that the comparative sample 3-4 is more easy to be worn, thereby leading to a shortened service life. The maximum static pressure and bonding surface shear strength of the comparative sample 3-4 are lower than those in the examples, and the main reason for this phenomenon may be that: in the comparative sample 3, the volume ratio of the metal component is too low, and the volume ratios of the carbon component and the ceramic component are both too high; in the comparative sample 4, the volume ratio of the carbon component is too high.

[0208] In Comparative Example 5, the proportion of carbon component and ceramic component is too high, and the proportion of metal component is too low, which results in that the metal component cannot combine the carbon component and the ceramic component sufficiently, and the green body cannot be formed in the pressing process.

[0209] The wear rates of the control samples 6-9 obtained in Comparative Examples 6-9 are high, wherein the wear rate of the control sample 6 is 2.65 x 10 -7 cm 3 / J, the wear rate of the control sample 7 is 2.58 x 10 -7 cm 3 / J, the wear rate of the control sample 8 is 2.51 x 10 -7 cm 3 / J, and the wear rate of the control sample 9 is 2.53 x 10 -7 cm 3 / J, which are all higher than the wear rates of the test samples obtained in the examples, and the high wear rate can easily result in short service life. The reason for the above-mentioned situation can be that the sintering temperature and sintering time are not properly controlled in the sintering process, thereby adversely affecting the wear rate of the obtained control samples.

[0210] The specific embodiments are only an explanation of the present application, and are not a limitation of the present application, and those skilled in the art can make modifications to the embodiments without creative contribution after reading the present specification, but as long as the modifications are within the scope of the claims of the present application, they are protected by the patent law.

Claims

1. A carbon-ceramic-copper alloy powder metallurgical sintered friction material, characterized in that, The raw material is composed of the following components in volume percentage: Carbon component 39.4-45.9%; Ceramic component 24.2-28.4%; Metal component 25.7-36.4%; In the carbon component, in volume percentage, Natural flake graphite 2.1-2.5%; 30-50 mesh artificial granular graphite 19.2-22.3%; 50-100 mesh artificial granular graphite 4.3-5%; 100-200 mesh artificial granular graphite 3.2-3.7%; Carbon fiber powder 5.3-6.2%; Petroleum coke 5.3-6.2%; In the ceramic component, in volume percentage, Zirconite sand 8.2-9.8%; Alumina 2.4-2.8%; Quartz powder 3.1-3.6%; Zirconium dioxide 5.2-6.1%; Silicon carbide 3.1-3.6%; Potassium feldspar powder 2.2-2.5%; In the metal component, in volume percentage, Copper powder 18.3-25.8%; Tin powder 2-2.8%; Zinc powder 1.5-2.2%; Nickel powder 1.1-1.6%; Iron powder 2.8-4.0%.

2. The production process of carbon-ceramic-copper alloy powder metallurgical sintered friction material according to claim 1, characterized in that, The method comprises the following steps: Step one, preliminary partial mixing: the copper powder in the metal component is crushed and mixed with the molding component completely volatilized during sintering to obtain a mixed initial material with a particle size not less than 600 mesh; Step two, re-mixing: after mixing the mixed initial material, the ceramic component, and the remaining metal component for 1-2 h, the carbon component is added and the mixing is continued for 20-25 min to obtain the mixed raw material; Step three, pressing the green body: the mixed raw material is pressed at 90-95 ℃ and 8-90 MPa to obtain a thin sheet green body; Step four, sintering and cooling: the thin sheet green body is sintered in three stages under gas protection, the sintering temperature gradually increases from 350 ℃ to 910 ℃, the sintering time is 230-240 min, and the sintering pressure is 2.8-3.1 MPa; cooling to obtain a carbon-ceramic sintered metal friction material.

3. The production method of carbon-ceramic-copper alloy powder metallurgy sintered friction material according to claim 2, characterized in that, The molding component in step one is rosin powder and white oil, the rosin powder accounts for 1.8% of the total volume of the raw material, and the white oil accounts for 1.55% of the total volume of the raw material; during the pressing process of step three, pre-pressing is performed at a pressure of 8-9 MPa for 12-15 s, and then pressing is performed at a pressure of 90-95 MPa for 2-3 s.

4. The production method of carbon-ceramic-copper alloy powder metallurgy sintered friction material according to claim 2, characterized in that, In step four, the gas is hydrogen-nitrogen protective gas composed of 8-25% hydrogen and the balance of nitrogen.

5. The method of producing a carbon-ceramic-copper alloy powder metallurgy sintered friction material according to claim 2, characterized by, The three-stage sintering in step four comprises: first-stage sintering at a sintering temperature of 350 ℃ for 20-30 min; second-stage sintering at a sintering temperature of 650 ℃ for 60-70 min; and third-stage sintering at a sintering temperature of 910 ℃ for 140-150 min.

6. The production method of carbon-ceramic-copper alloy powder metallurgy sintered friction material according to claim 5, characterized in that, In step four, during the temperature increasing process of the third-stage sintering, pressure treatment is performed at a pressure of 2.8-3.1 MPa; during the cooling process of step four, the pressure is removed after cooling to below 550 ℃.

7. The method of producing a carbon-ceramic-copper alloy powder metallurgy sintered friction material according to claim 2, characterized by, Before the step four starts sintering, spread the adhesive layer powder on the steel back of the pre-sintering equipment, and form the adhesive layer on the plane of the adhered steel back after pre-sintering; the adhesive layer powder is composed of the following components in mass percentage: 200 mesh copper powder 86.5%; Tin powder 12%; Zinc powder 1.5%; The amount of the binder layer powder used is 3-4 g / dm 2 The pre-sintering temperature is 800°C, and the sintering time in the mesh belt furnace is 15 min. In the step four, the thin slice green body is subjected to three-stage sintering treatment.

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