Carbon ceramic brake disc and method for manufacturing the same

Abstract

This invention discloses a carbon-ceramic brake disc and its preparation method, relating to the field of carbon-ceramic brake disc technology. This invention uses plain weave fabric instead of non-woven fabric, increasing the structural strength. Furthermore, the friction layer uses a mesh, solving the defect of easy shedding of non-woven fabric on the friction surface. The mesh fiber content is significantly reduced, increasing the ceramic content on the friction surface, thereby improving the material's wear performance. This invention prepares a wear-resistant magnesium hydroxysilicate, then combines it with porous molybdenum disulfide. By adding ferric chloride and ferric chloride tetrahydrate, the porous molybdenum disulfide-magnesium hydroxysilicate composite is loaded with iron oxide, further improving the strength and wear resistance of the carbon-ceramic brake disc.

Description

Technical Field

[0001] This invention relates to the field of carbon ceramic brake disc technology, specifically a carbon ceramic brake disc and its preparation method. Background Technology

[0002] In modern high-performance vehicles, especially in racing, military, and aerospace applications, the requirements for braking systems are becoming increasingly stringent. As a crucial component of the braking system, the brake disc's wear resistance, strength, and thermal stability directly impact braking safety and reliability. Traditional cast iron brake discs, due to their poor wear resistance, are increasingly unable to meet the demands of high-strength, long-term use. In recent years, carbon-ceramic composite materials, as a novel brake disc material, have been widely adopted in high-end fields such as aerospace and racing due to their high strength, high-temperature resistance, resistance to thermal fading, and low coefficient of thermal expansion.

[0003] However, the manufacturing process of carbon-ceramic brake discs still faces many challenges, including material uniformity, molding difficulty, and high costs. In particular, improving their wear resistance and strength to further enhance braking performance remains a key challenge in technological development. Therefore, developing a new type of wear-resistant, high-strength carbon-ceramic brake disc and its preparation method has become an urgent need for industry technological development. This would not only improve the service life and operational stability of brake discs but also reduce vehicle maintenance costs and enhance the safety and reliability of braking systems.

[0004] In summary, to solve the above problems, the present invention provides a carbon ceramic brake disc and its preparation method. Summary of the Invention

[0005] The purpose of this invention is to provide a carbon ceramic brake disc and its preparation method to solve the problems raised in the prior art.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A method for preparing a carbon-ceramic brake disc includes the following steps:

[0008] Step 1: Take phenolic resin B, silica powder, ceramic powder, and porous molybdenum disulfide-magnesium hydroxysilicate composite, adjust the pH value to 11-12, and ball mill for 46-48 hours to obtain a mixed slurry.

[0009] Step 2: Stack plain weave fabric and fusible mesh in sequence to obtain an intermediate layer; then lay fusible mesh on both the top and bottom surfaces of the intermediate layer and needle punch it to obtain a fiber preform.

[0010] Step 3: Immerse the fiber preform in the mixed slurry for 10-15 minutes, remove and dry it, keep it at 150℃ and 30MPa for 30-40 minutes, then pyrolyze it at 1000-1100℃ and keep it at 1800℃ for 50-60 minutes to process it into the shape of a brake disc. Then, perform silicon infiltration treatment in a vacuum furnace, keep it at 1300-1600℃, introduce nitrogen to 0.1MPa, cool it, and grind it to obtain a carbon ceramic brake disc.

[0011] A more optimized method for preparing the porous molybdenum disulfide-magnesium hydroxysilicate composite is as follows: take porous molybdenum disulfide, magnesium hydroxysilicate, and sodium alginate solution, and disperse them by ultrasonication to obtain a mixture A; take ferric chloride, ferric chloride tetrahydrate, and deionized water, stir evenly, add dropwise to mixture A, heat to 60-65℃, react for 40-50 min, freeze dry, and grind to obtain the porous molybdenum disulfide-magnesium hydroxysilicate composite.

[0012] A more optimized method for preparing the porous molybdenum disulfide is as follows: ammonium heptamolybdate, thiourea, and deionized water are taken, ultrasonically treated for 5-10 minutes, reacted at 195-200℃ for 22-24 hours, cooled, washed, and dried to obtain porous molybdenum disulfide.

[0013] A more optimized method for preparing the magnesium hydroxysilicate is as follows: take magnesium oxide, silicon dioxide, and distilled water, stir evenly, add sodium hydroxide solution, heat to 200℃ and react for 10-12 hours, cool to 25-30℃, wash, dry, grind, and ball mill to obtain magnesium hydroxysilicate.

[0014] A more optimized method for preparing phenolic resin B is as follows: take phenolic resin A, ethanol, acetone, and hexamethylenetetramine, mix them evenly, and obtain phenolic resin B.

[0015] A more optimized method for preparing phenolic resin A is as follows: take ammonia water, deionized water, and ethanol, stir for 60-70 min, add resorcinol and diethylenetriamine, stir for 30-40 min, add formaldehyde solution dropwise, continue stirring for 22-24 h, centrifuge, wash, and dry to obtain phenolic resin A.

[0016] Ideally, the mass ratio of phenolic resin A, ethanol, acetone, and hexamethylenetetramine is 1:1:1:0.1.

[0017] Ideally, the ceramic powder is any one of SiC, B4C, and BN; the particle size of the ceramic powder is 0.5-5μm.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] 1. This invention uses plain weave fabric instead of non-woven fabric, which increases the strength of the structural parts. On the other hand, the friction layer uses a mesh, which solves the defect of non-woven fabric on the friction surface being easy to fall off. Moreover, the fiber content of the mesh is greatly reduced, which increases the ceramic content on the friction surface, thereby improving the wear performance of the material. The uniform fiber distribution of the mesh structure improves the stability of the friction coefficient of the material.

[0020] This invention adds a process of introducing nitrogen gas at 1300-1600℃ and 0.1MPa, which generates silicon nitride by reacting nitrogen with silicon. By utilizing the non-wetting property of silicon nitride with silicon, the silicon slag on the brake disc surface can be effectively reduced, thereby improving the product qualification rate.

[0021] Adding silicon powder allows it to react with resin carbon to form a SiC barrier layer, slowing down the reaction rate of subsequent silicon diffusion treatment, resulting in more uniform silicon diffusion on the brake disc and improving the product qualification rate.

[0022] 2. This invention prepares a magnesium hydroxysilicate with excellent wear resistance, and then combines the magnesium hydroxysilicate with porous molybdenum disulfide. By adding ferric chloride and ferric chloride tetrahydrate, the porous molybdenum disulfide-magnesium hydroxysilicate composite is loaded with iron oxide, which further improves the strength and wear resistance of the carbon ceramic brake disc.

[0023] 3. The present invention uses diethylenetriamine to prepare a phenolic resin B. The addition of diethylenetriamine improves the chelation of phenolic resin B with porous molybdenum disulfide-magnesium hydroxysilicate composite, thereby improving the dispersion performance of porous molybdenum disulfide-magnesium hydroxysilicate composite and improving the strength and wear resistance of carbon ceramic brake disc. Detailed Implementation

[0024] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] The types and manufacturers of the materials involved in this invention are not subject to any specific limitations. Exemplary examples include: plain weave fabric: polyester-cotton plain weave fabric, item number: XT-A-04; available from Jinzhou Xinteng Textile Distribution Center; wire mesh: needle-punched wire mesh preform, item number: WT-YZT-1; available from Jiaxing Naco New Materials Co., Ltd.; magnesium oxide: 40nm particle size, available from Shuitian Materials Technology Co., Ltd.; silicon dioxide: 40nm particle size, available from Shuitian Materials Technology Co., Ltd.; silicon powder: 0.3um, available from Jiangsu Huimai Powder Technology Co., Ltd.

[0026] Example 1: A method for preparing a carbon ceramic brake disc, comprising the following steps:

[0027] Step 1: Preparation of fiber preforms:

[0028] Plain weave fabric and nylon mesh are layered sequentially to form an intermediate layer; then, a 5mm thick nylon mesh is laid flat on both the top and bottom surfaces of the intermediate layer and needle-punched to obtain a fiber preform; the needle-punching density is 10 needles / cm. 2 The bulk density of the fiber preform is 0.6 g / cm³. 3 The mass ratio of the fusible mesh to the plain weave fabric in the intermediate layer is 2:8;

[0029] Step 2: Preparation of magnesium hydroxysilicate:

[0030] Take 4.5g magnesium oxide, 4.5g silicon dioxide, and 400mL distilled water, stir well, add 13mL of 1mol / L sodium hydroxide solution, heat to 200℃ and react for 11h, cool to 27℃, wash, dry, grind, and ball mill to obtain magnesium hydroxysilicate;

[0031] Step 3: Preparation of porous molybdenum disulfide:

[0032] Take 1.2g of ammonium heptamolybdate, 0.5g of thiourea, and 60mL of deionized water, sonicate for 8min, react at 198℃ for 23h, cool, wash, and dry to obtain porous molybdenum disulfide;

[0033] Step 4: Preparation of porous molybdenum disulfide-magnesium hydroxysilicate composite:

[0034] Take 0.05g of porous molybdenum disulfide, 0.6g of magnesium hydroxysilicate, and 20mL of 1% sodium alginate solution, and disperse them by ultrasonication to obtain mixture A; take 3g of ferric chloride, 2g of ferric chloride tetrahydrate, and 100mL of deionized water, stir evenly, add dropwise to mixture A, heat to 62℃, react for 45min, freeze dry, and grind to obtain porous molybdenum disulfide-magnesium hydroxysilicate composite.

[0035] Step 5: Preparation of phenolic resin A:

[0036] Take 0.6 mL of ammonia water, 100 mL of deionized water, and 40 mL of ethanol, stir for 60-70 min, add 1 g of resorcinol and 1 mL of diethylenetriamine, stir for 35 min, add 1.5 mL of formaldehyde solution dropwise, continue stirring for 23 h, centrifuge, wash, and dry to obtain phenolic resin A;

[0037] Step Six: Preparation of Phenolic Resin B:

[0038] Phenolic resin A, ethanol, acetone, and hexamethylenetetramine were mixed in a weight ratio of 1:1:1:0.1 to obtain phenolic resin B.

[0039] Step 7: Preparation of the mixed slurry:

[0040] Take 100g of phenolic resin B, 5g of silica powder, 32g of ceramic powder SiC, and 2g of porous molybdenum disulfide-magnesium hydroxysilicate composite, add ammonia and hydrochloric acid to adjust the pH to 11, and ball mill for 47h to obtain a mixed slurry.

[0041] Step 8: Preparation of carbon ceramic brake discs:

[0042] The fiber preform was immersed in the mixed slurry for 12 minutes under vacuum conditions, then removed and dried. It was then held at 150℃ and 30MPa for 30 minutes, thermally decomposed at 1000℃, and held at 1800℃ for 55 minutes to form a brake disc shape. Then, it was subjected to silicon infiltration in a vacuum furnace at 1650℃ for 5 hours. Nitrogen gas was introduced at 1500℃ to 0.1MPa, and the mixture was cooled and ground to obtain a carbon-ceramic brake disc.

[0043] Example 2: A method for preparing a carbon ceramic brake disc, comprising the following steps:

[0044] Step 1: Preparation of fiber preforms:

[0045] Plain weave fabric and nylon mesh are layered sequentially to form an intermediate layer; then, a 5mm thick nylon mesh is laid flat on both the top and bottom surfaces of the intermediate layer and needle-punched to obtain a fiber preform; the needle-punching density is 10 needles / cm. 2 The bulk density of the fiber preform is 0.6 g / cm³. 3 The mass ratio of the fusible mesh to the plain weave fabric in the intermediate layer is 2:8;

[0046] Step 2: Preparation of magnesium hydroxysilicate:

[0047] Take 4.5g magnesium oxide, 4.5g silicon dioxide, and 400mL distilled water, stir well, add 13mL of 1mol / L sodium hydroxide solution, heat to 200℃ and react for 10h, cool to 25℃, wash, dry, grind, and ball mill to obtain magnesium hydroxysilicate;

[0048] Step 3: Preparation of porous molybdenum disulfide:

[0049] Take 1.2g ammonium heptamolybdate, 0.5g thiourea, and 60mL deionized water, sonicate for 5min, react at 195℃ for 22h, cool, wash, and dry to obtain porous molybdenum disulfide;

[0050] Step 4: Preparation of porous molybdenum disulfide-magnesium hydroxysilicate composite:

[0051] Take 0.05g of porous molybdenum disulfide, 0.6g of magnesium hydroxysilicate, and 20mL of 1% sodium alginate solution, and disperse them by ultrasonication to obtain mixture A; take 3g of ferric chloride, 2g of ferric chloride tetrahydrate, and 100mL of deionized water, stir evenly, add dropwise to mixture A, heat to 60℃, react for 40min, freeze dry, and grind to obtain porous molybdenum disulfide-magnesium hydroxysilicate composite.

[0052] Step 5: Preparation of phenolic resin A:

[0053] Take 0.6 mL of ammonia water, 100 mL of deionized water, and 40 mL of ethanol, stir for 60 min, add 1 g of resorcinol and 1 mL of diethylenetriamine, stir for 30 min, add 1.5 mL of formaldehyde solution dropwise, continue stirring for 22 h, centrifuge, wash, and dry to obtain phenolic resin A;

[0054] Step Six: Preparation of Phenolic Resin B:

[0055] Phenolic resin A, ethanol, acetone, and hexamethylenetetramine were mixed in a weight ratio of 1:1:1:0.1 to obtain phenolic resin B.

[0056] Step 7: Preparation of the mixed slurry:

[0057] Take 100g of phenolic resin B, 5g of silica powder, 32g of ceramic powder B4C, and 2g of porous molybdenum disulfide-magnesium hydroxysilicate composite, add ammonia and hydrochloric acid to adjust the pH to 11, and ball mill for 46h to obtain a mixed slurry.

[0058] Step 8: Preparation of carbon ceramic brake discs:

[0059] The fiber preform was immersed in the mixed slurry for 10 minutes under vacuum conditions, then removed and dried. It was then held at 150℃ and 30MPa for 30 minutes, thermally decomposed at 1000℃, and held at 1800℃ for 50 minutes to form a brake disc shape. Then, it was subjected to silicon infiltration in a vacuum furnace at 1650℃ for 5 hours. Nitrogen gas was introduced at 1300℃ to 0.1MPa, and the mixture was cooled and ground to obtain a carbon-ceramic brake disc.

[0060] Example 3: A method for preparing a carbon ceramic brake disc, comprising the following steps:

[0061] Step 1: Preparation of fiber preforms:

[0062] Plain weave fabric and nylon mesh are layered sequentially to form an intermediate layer; then, a 5mm thick nylon mesh is laid flat on both the top and bottom surfaces of the intermediate layer and needle-punched to obtain a fiber preform; the needle-punching density is 10 needles / cm. 2 The bulk density of the fiber preform is 0.6 g / cm³. 3The mass ratio of the fusible mesh to the plain weave fabric in the intermediate layer is 2:8;

[0063] Step 2: Preparation of magnesium hydroxysilicate:

[0064] Take 4.5g magnesium oxide, 4.5g silicon dioxide, and 400mL distilled water, stir well, add 13mL of 1mol / L sodium hydroxide solution, heat to 200℃ and react for 12h, cool to 30℃, wash, dry, grind, and ball mill to obtain magnesium hydroxysilicate;

[0065] Step 3: Preparation of porous molybdenum disulfide:

[0066] Take 1.2g ammonium heptamolybdate, 0.5g thiourea, and 60mL deionized water, sonicate for 10min, react at 200℃ for 24h, cool, wash, and dry to obtain porous molybdenum disulfide;

[0067] Step 4: Preparation of porous molybdenum disulfide-magnesium hydroxysilicate composite:

[0068] Take 0.05g of porous molybdenum disulfide, 0.6g of magnesium hydroxysilicate, and 20mL of 1% sodium alginate solution, and disperse them by ultrasonication to obtain mixture A; take 3g of ferric chloride, 2g of ferric chloride tetrahydrate, and 100mL of deionized water, stir evenly, add dropwise to mixture A, heat to 65℃, react for 50min, freeze dry, and grind to obtain porous molybdenum disulfide-magnesium hydroxysilicate composite;

[0069] Step 5: Preparation of phenolic resin A:

[0070] Take 0.6 mL of ammonia water, 100 mL of deionized water, and 40 mL of ethanol, stir for 70 min, add 1 g of resorcinol and 1 mL of diethylenetriamine, stir for 40 min, add 1.5 mL of formaldehyde solution dropwise, continue stirring for 24 h, centrifuge, wash, and dry to obtain phenolic resin A;

[0071] Step Six: Preparation of Phenolic Resin B:

[0072] Phenolic resin A, ethanol, acetone, and hexamethylenetetramine were mixed in a weight ratio of 1:1:1:0.1 to obtain phenolic resin B.

[0073] Step 7: Preparation of the mixed slurry:

[0074] Take 100g of phenolic resin B, 5g of silica powder, 32g of ceramic powder BN, and 2g of porous molybdenum disulfide-magnesium hydroxysilicate composite, add ammonia and hydrochloric acid to adjust the pH to 11, and ball mill for 48h to obtain a mixed slurry.

[0075] Step 8: Preparation of carbon ceramic brake discs:

[0076] The fiber preform was immersed in the mixed slurry for 15 minutes under vacuum conditions, then removed and dried. It was then held at 150℃ and 30MPa for 30 minutes, thermally decomposed at 1100℃, and held at 1800℃ for 60 minutes to form a brake disc shape. Then, it was subjected to silicon infiltration in a vacuum furnace at 1650℃ for 5 hours. Nitrogen gas was introduced at 1600℃ to 0.1MPa, and the mixture was cooled and ground to obtain a carbon-ceramic brake disc.

[0077] Comparative Example 1: No magnesium hydroxysilicate added, otherwise the same as Example 1:

[0078] Step 1: Preparation of fiber preforms:

[0079] Plain weave fabric and nylon mesh are layered sequentially to form an intermediate layer; then, a 5mm thick nylon mesh is laid flat on both the top and bottom surfaces of the intermediate layer and needle-punched to obtain a fiber preform; the needle-punching density is 10 needles / cm. 2 The bulk density of the fiber preform is 0.6 g / cm³. 3 The mass ratio of the fusible mesh to the plain weave fabric in the intermediate layer is 2:8;

[0080] Step 2: Preparation of porous molybdenum disulfide:

[0081] Take 1.2g of ammonium heptamolybdate, 0.5g of thiourea, and 60mL of deionized water, sonicate for 8min, react at 198℃ for 23h, cool, wash, and dry to obtain porous molybdenum disulfide;

[0082] Step 3: Preparation of modified porous molybdenum disulfide:

[0083] Take 0.05g of porous molybdenum disulfide and 20mL of 1% sodium alginate solution, and disperse them by ultrasonication to obtain mixture A; take 3g of ferric chloride, 2g of ferric chloride tetrahydrate and 100mL of deionized water, stir evenly, add dropwise to mixture A, heat to 62℃, react for 45min, freeze dry and grind to obtain modified porous molybdenum disulfide;

[0084] Step 4: Preparation of phenolic resin A:

[0085] Take 0.6 mL of ammonia water, 100 mL of deionized water, and 40 mL of ethanol, stir for 60-70 min, add 1 g of resorcinol and 1 mL of diethylenetriamine, stir for 35 min, add 1.5 mL of formaldehyde solution dropwise, continue stirring for 23 h, centrifuge, wash, and dry to obtain phenolic resin A;

[0086] Step 5: Preparation of phenolic resin B:

[0087] Phenolic resin A, ethanol, acetone, and hexamethylenetetramine were mixed in a weight ratio of 1:1:1:0.1 to obtain phenolic resin B.

[0088] Step Six: Preparation of the Mixed Slurry:

[0089] Take 100g of phenolic resin B, 5g of silica powder, 32g of ceramic powder SiC, and 2g of modified porous molybdenum disulfide. Add ammonia and hydrochloric acid to adjust the pH value to 11. Ball mill for 47h to obtain a mixed slurry.

[0090] Step 7: Preparation of carbon ceramic brake discs:

[0091] The fiber preform was immersed in the mixed slurry for 12 minutes under vacuum conditions, then removed and dried. It was then held at 150℃ and 30MPa for 30 minutes, thermally decomposed at 1000℃, and held at 1800℃ for 55 minutes to form a brake disc shape. Then, it was subjected to silicon infiltration in a vacuum furnace at 1650℃ for 5 hours. Nitrogen gas was introduced at 1500℃ to 0.1MPa, and the mixture was cooled and ground to obtain a carbon-ceramic brake disc.

[0092] Comparative Example 2: No iron oxide was loaded onto the porous molybdenum disulfide-magnesium hydroxysilicate composite; all other aspects were the same as in Example 1.

[0093] Step 1: Preparation of fiber preforms:

[0094] Plain weave fabric and nylon mesh are layered sequentially to form an intermediate layer; then, a 5mm thick nylon mesh is laid flat on both the top and bottom surfaces of the intermediate layer and needle-punched to obtain a fiber preform; the needle-punching density is 10 needles / cm. 2 The bulk density of the fiber preform is 0.6 g / cm³. 3 The mass ratio of the fusible mesh to the plain weave fabric in the intermediate layer is 2:8;

[0095] Step 2: Preparation of magnesium hydroxysilicate:

[0096] Take 4.5g magnesium oxide, 4.5g silicon dioxide, and 400mL distilled water, stir well, add 13mL of 1mol / L sodium hydroxide solution, heat to 200℃ and react for 11h, cool to 27℃, wash, dry, grind, and ball mill to obtain magnesium hydroxysilicate;

[0097] Step 3: Preparation of porous molybdenum disulfide:

[0098] Take 1.2g of ammonium heptamolybdate, 0.5g of thiourea, and 60mL of deionized water, sonicate for 8min, react at 198℃ for 23h, cool, wash, and dry to obtain porous molybdenum disulfide;

[0099] Step 4: Preparation of porous molybdenum disulfide-magnesium hydroxysilicate composite:

[0100] Take 0.05g of porous molybdenum disulfide, 0.6g of magnesium hydroxysilicate, and 20mL of sodium alginate solution with a mass concentration of 1%, disperse them by ultrasonication to obtain mixture A, take 100mL of deionized water, add it dropwise to mixture A, heat to 62℃, react for 45min, freeze dry and grind to obtain porous molybdenum disulfide-magnesium hydroxysilicate composite.

[0101] Step 5: Preparation of phenolic resin A:

[0102] Take 0.6 mL of ammonia water, 100 mL of deionized water, and 40 mL of ethanol, stir for 60-70 min, add 1 g of resorcinol and 1 mL of diethylenetriamine, stir for 35 min, add 1.5 mL of formaldehyde solution dropwise, continue stirring for 23 h, centrifuge, wash, and dry to obtain phenolic resin A;

[0103] Step Six: Preparation of Phenolic Resin B:

[0104] Phenolic resin A, ethanol, acetone, and hexamethylenetetramine were mixed in a weight ratio of 1:1:1:0.1 to obtain phenolic resin B.

[0105] Step 7: Preparation of the mixed slurry:

[0106] Take 100g of phenolic resin B, 5g of silica powder, 32g of ceramic powder SiC, and 2g of porous molybdenum disulfide-magnesium hydroxysilicate composite, add ammonia and hydrochloric acid to adjust the pH to 11, and ball mill for 47h to obtain a mixed slurry.

[0107] Step 8: Preparation of carbon ceramic brake discs:

[0108] The fiber preform was immersed in the mixed slurry for 12 minutes under vacuum conditions, then removed and dried. It was then held at 150℃ and 30MPa for 30 minutes, thermally decomposed at 1000℃, and held at 1800℃ for 55 minutes to form a brake disc shape. Then, it was subjected to silicon infiltration in a vacuum furnace at 1650℃ for 5 hours. Nitrogen gas was introduced at 1500℃ to 0.1MPa, and the mixture was cooled and ground to obtain a carbon-ceramic brake disc.

[0109] Comparative Example 3: Phenolic resin was not modified using diethylenetriamine; all other aspects were the same as in Example 1.

[0110] Step 1: Preparation of fiber preforms:

[0111] Plain weave fabric and nylon mesh are layered sequentially to form an intermediate layer; then, a 5mm thick nylon mesh is laid flat on both the top and bottom surfaces of the intermediate layer and needle-punched to obtain a fiber preform; the needle-punching density is 10 needles / cm. 2 The bulk density of the fiber preform is 0.6 g / cm³. 3The mass ratio of the fusible mesh to the plain weave fabric in the intermediate layer is 2:8;

[0112] Step 2: Preparation of magnesium hydroxysilicate:

[0113] Take 4.5g magnesium oxide, 4.5g silicon dioxide, and 400mL distilled water, stir well, add 13mL of 1mol / L sodium hydroxide solution, heat to 200℃ and react for 11h, cool to 27℃, wash, dry, grind, and ball mill to obtain magnesium hydroxysilicate;

[0114] Step 3: Preparation of porous molybdenum disulfide:

[0115] Take 1.2g of ammonium heptamolybdate, 0.5g of thiourea, and 60mL of deionized water, sonicate for 8min, react at 198℃ for 23h, cool, wash, and dry to obtain porous molybdenum disulfide;

[0116] Step 4: Preparation of porous molybdenum disulfide-magnesium hydroxysilicate composite:

[0117] Take 0.05g of porous molybdenum disulfide, 0.6g of magnesium hydroxysilicate, and 20mL of 1% sodium alginate solution, and disperse them by ultrasonication to obtain mixture A; take 3g of ferric chloride, 2g of ferric chloride tetrahydrate, and 100mL of deionized water, stir evenly, add dropwise to mixture A, heat to 62℃, react for 45min, freeze dry, and grind to obtain porous molybdenum disulfide-magnesium hydroxysilicate composite.

[0118] Step 5: Preparation of phenolic resin:

[0119] Take 0.6 mL of ammonia water, 100 mL of deionized water, and 40 mL of ethanol, stir for 60-70 min, add 1 g of resorcinol, stir for 35 min, add 1.5 mL of formaldehyde solution dropwise, continue stirring for 23 h, centrifuge, wash, and dry to obtain phenolic resin.

[0120] Step Six: Preparation of Phenolic Resin B:

[0121] Phenolic resin, ethanol, acetone, and hexamethylenetetramine were mixed in a weight ratio of 1:1:1:0.1 to obtain phenolic resin B.

[0122] Step 7: Preparation of the mixed slurry:

[0123] Take 100g of phenolic resin B, 5g of silica powder, 32g of ceramic powder SiC, and 2g of porous molybdenum disulfide-magnesium hydroxysilicate composite, add ammonia and hydrochloric acid to adjust the pH to 11, and ball mill for 47h to obtain a mixed slurry.

[0124] Step 8: Preparation of carbon ceramic brake discs:

[0125] The fiber preform was immersed in the mixed slurry for 12 minutes under vacuum conditions, then removed and dried. It was then held at 150℃ and 30MPa for 30 minutes, thermally decomposed at 1000℃, and held at 1800℃ for 55 minutes to form a brake disc shape. Then, it was subjected to silicon infiltration in a vacuum furnace at 1650℃ for 5 hours. Nitrogen gas was introduced at 1500℃ to 0.1MPa, and the mixture was cooled and ground to obtain a carbon-ceramic brake disc.

[0126] experiment:

[0127] The carbon-ceramic brake discs prepared in Examples 1 to 3 and Comparative Examples 1 to 3 were subjected to performance tests. The shear strength of the carbon-ceramic brake discs was tested according to GB / T40388-2021 (Carbon / Carbon Composite Material Shear Strength Test), and the coefficient of friction of the carbon-ceramic brake discs was tested according to SAEJ2522-2003. The data obtained are shown in the table below:

[0128]

[0129] Conclusions: The data comparison in the table shows that in Comparative Example 1, without the addition of magnesium hydroxysilicate, the wear resistance and mechanical properties of the carbon-ceramic brake disc decreased. In Comparative Example 2, without loading iron oxide onto the porous molybdenum disulfide-magnesium hydroxysilicate composite, the dispersion of the porous molybdenum disulfide-magnesium hydroxysilicate composite was poor, affecting the strength and wear resistance of the carbon-ceramic brake disc. In Comparative Example 3, without using diethylenetriamine to modify the phenolic resin, the dispersion of the porous molybdenum disulfide-magnesium hydroxysilicate composite in the resin matrix was poor, and the strength and wear resistance of the carbon-ceramic brake disc also decreased. In Examples 1 to 3 of this invention, plain weave fabric was used instead of non-woven fabric, increasing the structural strength. Furthermore, a mesh was used for the friction layer, solving the problem of easy detachment of non-woven fabric on the friction surface. The significantly reduced fiber content of the mesh increased the ceramic content on the friction surface, thereby improving the material's wear resistance. This invention prepared a wear-resistant magnesium hydroxysilicate, which was then composited with porous molybdenum disulfide. The addition of ferric chloride and ferric chloride tetrahydrate resulted in the porous molybdenum disulfide-magnesium hydroxysilicate composite being loaded with iron(III) oxide, further improving the strength and wear resistance of the carbon-ceramic brake disc. This invention also used diethylenetriamine to prepare a phenolic resin B. The addition of diethylenetriamine improved the chelation between phenolic resin B and the porous molybdenum disulfide-magnesium hydroxysilicate composite, thereby improving the dispersion performance of the porous molybdenum disulfide-magnesium hydroxysilicate composite and further enhancing the strength and wear resistance of the carbon-ceramic brake disc.

[0130] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

Claims

1. A method for preparing a carbon-ceramic brake disc, characterized in that: Includes the following steps: Step 1: Take phenolic resin B, silica powder, ceramic powder, and porous molybdenum disulfide-magnesium hydroxysilicate composite, adjust the pH value to 11-12, and ball mill for 46-48 hours to obtain a mixed slurry. Step 2: Stack plain weave fabric and fusible mesh in sequence to obtain an intermediate layer; then lay fusible mesh on both the top and bottom surfaces of the intermediate layer and needle punch it to obtain a fiber preform. Step 3: Immerse the fiber preform in the mixed slurry for 10-15 minutes, remove and dry, hold at 150℃ and 30MPa for 30-40 minutes, pyrolyze at 1000-1100℃, hold at 1800℃ for 50-60 minutes, process into the shape of a brake disc, then perform silicon infiltration treatment in a vacuum furnace, hold at 1300-1600℃, introduce nitrogen to 0.1MPa, cool and grind to obtain a carbon ceramic brake disc; The porous molybdenum disulfide-magnesium hydroxysilicate composite is prepared as follows: porous molybdenum disulfide, magnesium hydroxysilicate, and sodium alginate solution are taken and ultrasonically dispersed to obtain mixture A; ferric chloride, ferric chloride tetrahydrate, and deionized water are taken, stirred evenly, and added dropwise to mixture A; the temperature is raised to 60-65℃, the reaction is carried out for 40-50 min, and the mixture is freeze-dried and ground to obtain the porous molybdenum disulfide-magnesium hydroxysilicate composite. The preparation method of the phenolic resin B is as follows: take phenolic resin A, ethanol, acetone and hexamethylenetetramine, mix them evenly to obtain phenolic resin B; The preparation method of the phenolic resin A is as follows: take ammonia water, deionized water and ethanol, stir for 60-70 min, add resorcinol and diethylenetriamine, stir for 30-40 min, add formaldehyde solution dropwise, continue stirring for 22-24 h, centrifuge, wash and dry to obtain phenolic resin A.

2. The method for preparing a carbon-ceramic brake disc according to claim 1, characterized in that: The porous molybdenum disulfide is prepared by taking ammonium heptamolybdate, thiourea, and deionized water, ultrasonically treating for 5-10 minutes, reacting at 195-200℃ for 22-24 hours, cooling, washing, and drying to obtain porous molybdenum disulfide.

3. The method for preparing a carbon-ceramic brake disc according to claim 1, characterized in that: The preparation method of the magnesium hydroxysilicate is as follows: take magnesium oxide, silicon dioxide and distilled water, stir evenly, add sodium hydroxide solution, heat to 200℃ and react for 10-12h, cool to 25-30℃, wash, dry, grind and ball mill to obtain magnesium hydroxysilicate.

4. The method for preparing a carbon ceramic brake disc according to claim 1, characterized in that: The mass ratio of phenolic resin A, ethanol, acetone, and hexamethylenetetramine is 1:1:1:0.

1.

5. The method for preparing a carbon-ceramic brake disc according to claim 1, characterized in that: The ceramic powder is any one of SiC, B4C, and BN; the particle size of the ceramic powder is 0.5-5μm.

6. A carbon-ceramic brake disc prepared by the method described in any one of claims 1-5.

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