Preparation method of carbon ceramic brake disc with composite friction layer and carbon ceramic brake disc

Abstract

The present application relates to ceramic products and its preparation method, specifically relates to a kind of carbon ceramic brake disc preparation method with composite friction layer and carbon ceramic brake disc, for solving the low material utilization rate of carbon ceramic brake disc manufacturing process, leading to the increase of production cost, restrict its large-scale application of the insufficient place.This carbon ceramic brake disc preparation method with composite friction layer, sequentially includes the following steps: carbon-carbon composite material preparation, rough machining, heat conduction function layer preparation, composite friction layer preparation, ceramization processing, finishing.The heat conduction function layer in the application can effectively reduce the disc surface temperature during braking, prolong the life of caliper and other peripheral accessories, and the composite friction layer component is uniform and can be designed, which can reduce noise and shaking during braking.In addition, the use of residual material head also improves the utilization rate of raw materials and reduces production cost.At the same time, the present application also discloses a kind of carbon ceramic brake disc with composite friction layer.

Description

TECHNICAL FIELD

[0001] The present application relates to a ceramic product and a preparation method thereof, in particular to a preparation method of a carbon ceramic brake disc with a composite friction layer and the carbon ceramic brake disc. BACKGROUND

[0002] As a new generation of high-performance materials, carbon ceramic composite materials successfully combine the advantages of carbon-carbon composite materials and ceramic matrix composite materials. This material has low density, high temperature resistance, long service life, and can work stably under high load and complex environment, and is widely considered as a promising brake material.

[0003] With the increasing demand for lightweight electric vehicles and the reduction of carbon ceramic brake disc manufacturing costs, its application has gradually expanded from high-end vehicles to new energy vehicles, commercial vehicles and special vehicles. Through technological innovation and large-scale production, domestic enterprises have effectively reduced production costs, making carbon ceramic brake discs increasingly competitive in the market.

[0004] The manufacture of carbon ceramic brake discs involves the formation of three-dimensional needle-punched preforms, as well as high-precision processes such as chemical vapor infiltration (CVI), precursor infiltration and conversion (PIP), and reactive melt infiltration (RMI). However, mechanical processing during these processes inevitably leads to material waste. For example, the material utilization rate of a brake disc with a diameter of 355 mm and a thickness of 28 mm after processing is only 35% to 45%, which significantly increases production costs and restricts its large-scale application. SUMMARY

[0005] The purpose of the present application is to solve the problem of low material utilization rate in the manufacturing process of carbon ceramic brake discs, which increases production costs and restricts its large-scale application, and to provide a preparation method of a carbon ceramic brake disc with a composite friction layer and the carbon ceramic brake disc.

[0006] In order to solve the above-mentioned problems of the prior art, the present application provides the following technical solutions:

[0007] A preparation method of a carbon ceramic brake disc with a composite friction layer, characterized in that it comprises the following steps:

[0008] Step 1: depositing a carbon matrix on a three-dimensional needle-punched preform by vapor deposition at a temperature of 600-1200°C to obtain a carbon-carbon composite material with a density of 1.4±0.05 g / cm 3 ;

[0009] Step 2: processing the carbon-carbon composite material into a carbon-carbon brake disc, and sequentially crushing the residual material head to obtain small-size carbon-carbon composite particles with a diameter of 100-300 μm and large-size carbon-carbon composite particles with a diameter of 300-500 μm;

[0010] Step 3, prepare a heat-conducting mixture according to specific mass ratio, the heat-conducting mixture including organic resin, curing agent, heat-conducting filler, large-size carbon-carbon composite particles, and silane coupling agent ethanol solution, and heat-press solidify the heat-conducting mixture on the surface of the carbon-carbon brake disc to form a heat-conducting functional layer;

[0011] Step 4, prepare a friction mixture according to specific mass ratio, the friction mixture including organic resin, curing agent, friction filler, small-size carbon-carbon composite particles, and silane coupling agent ethanol solution, and heat-press solidify the friction mixture on the surface of the carbon-carbon brake disc obtained in Step 3 to form a composite friction layer;

[0012] Step 5, place the carbon-carbon brake disc obtained in Step 4 in a high-temperature furnace for ceramization treatment, the temperature being 1200-1600℃ and the time being 1-4h, to obtain a carbon ceramic brake disc with a density of 2.0-2.8g / cm 3

[0013] Step 6, finish machining the carbon ceramic brake disc, clean away residual ceramization raw materials, and super-finish flat grind the friction surface to achieve the required surface smoothness and accuracy, to obtain a carbon ceramic brake disc with a composite friction layer.

[0014] Further, in Step 3, the mass ratio of the organic resin, curing agent, heat-conducting filler, large-size carbon-carbon composite particles, and silane coupling agent ethanol solution is respectively 80-120:5-20:20-50:50-100:5-10; the heat-conducting filler is at least one of iron, iron alloy, aluminum, aluminum alloy, copper, copper alloy, aluminum oxide, silicon oxide, diatomite, silicon carbide, boron carbide, mullite, boron nitride, aluminum nitride, and flake carbon.

[0015] Further, in Step 4, the mass ratio of the organic resin, curing agent, friction filler, small-size carbon-carbon composite particles, and silane coupling agent ethanol solution is respectively 80-120:5-20:20-50:40-80:4-8;

[0016] the friction filler is at least one of iron, copper, aluminum oxide, silicon oxide, silicon carbide, lead oxide, asbestos, mullite, graphite, boron nitride, and molybdenum disulfide.

[0017] Further, in Step 3, the heat-conducting mixture is configured as follows: first, add the large-size carbon-carbon composite particles and the silane coupling agent ethanol solution, and ball mill for 0.5-1h; then add the heat-conducting filler, and continue ball milling for 1-2h; finally, add the organic resin and the curing agent, and ball mill for 0.5-1h to obtain the heat-conducting mixture;

[0018] ​In step 4, the configuration of the friction mixture is as follows: first, the small-size carbon-carbon composite particles and the silane coupling agent ethanol solution are added and ball-milled for 0.5-1 h; then the friction filler is added and ball-milled for 1-2 h; finally, the organic resin and the curing agent are added and ball-milled for 0.5-1 h, to obtain the friction mixture.

[0019] Further, in steps 3 and 4, the organic resin is furan resin or phenolic resin, the curing agent is xylenesulfonic acid or urotropine, and the solute of the silane coupling agent ethanol solution is one of aminosilane, thiol silane and methyl vinyl silane, with a mass fraction of 1%.

[0020] Further, in steps 3 and 4, the hot-pressing curing has a hot-pressing pressure of 1-5 MPa, a curing temperature of 150-200 DEG C and a curing time of 1-3 h.

[0021] In step 3, the thickness of the heat-conducting functional layer is 1-3 mm.

[0022] In step 4, the thickness of the composite friction layer is 1-2 mm.

[0023] Further, in step 5, the ceramicization raw material for the ceramicization treatment is at least one of silicon powder, iron powder, copper powder, silicon-iron alloy powder and copper-iron alloy powder.

[0024] Meanwhile, the application also provides a carbon-ceramic brake disc with a composite friction layer, which is prepared by the above method.

[0025] Compared with the prior art, the application has the following advantages:

[0026] (1) The application provides a method for preparing a carbon-ceramic brake disc with a composite friction layer, which comprises the following steps in sequence: carbon-carbon composite material preparation, rough machining, heat-conducting functional layer preparation, composite friction layer preparation, ceramicization treatment and fine machining.

[0027] (2) The carbon ceramic brake disc with a composite friction layer combines the advantages of three-dimensional needling structure and mold pressing structure, the middle bearing layer adopts a three-dimensional needling preform, the brake disc has better mechanical properties, and the safety and reliability of the connection are ensured; the composite friction layer is prepared by a mold pressing process, part of the mechanical properties is sacrificed, and more stable friction braking performance is obtained; and the functional powder is added by the mold pressing method, which is simpler than adding the functional powder into the three-dimensional needling preform, and the processability is better.

[0028] (3) The carbon ceramic brake disc with a composite friction layer has the characteristics that the end value of the brake disc braking temperature is obviously reduced in the characteristic value stage, the brake disc braking temperature curve rises slowly in the thermal recession stage, it is indicated that the heat dissipation performance of the carbon ceramic brake disc with a composite friction layer is excellent, the anti-thermal recession ability is stronger, the carbon ceramic brake disc with a composite friction layer can still maintain good friction performance and pressure stability in the high-temperature stage, and is suitable for long-time high-frequency braking scenes.

[0029] (4) In the carbon ceramic brake disc with a composite friction layer, the composite friction layer prepared by the hot pressing process is uniform in composition, can be designed according to requirements, and has good braking stability; and the existing carbon ceramic brake disc usually adopts a three-dimensional needling preform, and the component proportions of the net tire layer and the weftless cloth layer are different, so the net tire and the weftless cloth layer are prone to alternating friction in the friction process, and obvious noise and shaking are caused. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 It is a friction coefficient change (blue) and brake disc braking temperature change (red) test result schematic diagram of the experimental group in the characteristic value 1 stage in the carbon ceramic brake disc preparation method embodiment one of the application;

[0031] Figure 2 It is a friction coefficient change (blue) and brake disc braking temperature change (red) test result schematic diagram of the control group in the characteristic value 1 stage in the carbon ceramic brake disc preparation method embodiment one of the application;

[0032] Figure 3 It is a friction coefficient change (blue) and brake disc braking temperature change (red) test result schematic diagram of the experimental group in the characteristic value 2 stage in the carbon ceramic brake disc preparation method embodiment one of the application;

[0033] Figure 4 It is a friction coefficient change (blue) and brake disc braking temperature change (red) test result schematic diagram of the control group in the characteristic value 2 stage in the carbon ceramic brake disc preparation method embodiment one of the application;

[0034] Figure 5 It is a friction coefficient change (blue) and brake disc braking temperature change (red) test result schematic diagram of the experimental group in the characteristic value 3 stage in the carbon ceramic brake disc preparation method embodiment one of the application;

[0035] Figure 6A schematic diagram of the test results of the friction coefficient change (blue) and brake disc braking temperature change (red) of the control group in the characteristic value 3 stage of the embodiment one of the present application;

[0036] Figure 7 A schematic diagram of the test results of the friction coefficient change (blue), brake disc braking temperature change (red) and piston pressure value change (green) of the experimental group in the heat decay 1 stage of the embodiment one of the present application;

[0037] Figure 8 A schematic diagram of the test results of the friction coefficient change (blue), brake disc braking temperature change (red) and piston pressure value change (green) of the control group in the heat decay 1 stage of the embodiment one of the present application. DETAILED DESCRIPTION

[0038] The present application will be further described below in conjunction with the accompanying drawings and exemplary embodiments.

[0039] Embodiment one

[0040] A preparation method of a carbon ceramic brake disc with a composite friction layer, comprising the following steps:

[0041] Step 1, preparation of carbon-carbon composite material;

[0042] A carbon matrix is deposited on a three-dimensional needling preform by a gas deposition method at a temperature of 950℃ to obtain a carbon-carbon composite material with a density of 1.4g / cm 3 ;

[0043] The deposition temperature can be set to a minimum of 600℃ and a maximum of 1200℃; and the density of the carbon-carbon composite material can be 1.4±0.05g / cm 3 , so as to provide moderate porosity, which is beneficial to finding a good balance among the mechanical properties, composite layer bonding force and ceramic efficiency of the carbon ceramic brake disc with the composite friction layer, and ensures the lightweight, high performance and durability of the brake disc;

[0044] The carbon source gas used for deposition is petroleum liquefied gas, and the carrier gas used is argon;

[0045] Step 2, rough machining;

[0046] The carbon-carbon composite material is machined into a carbon-carbon brake disc, and the residual material head is sequentially subjected to crushing treatment to obtain small-size carbon-carbon composite particles with a diameter of 100-300μm and large-size carbon-carbon composite particles with a diameter of 300-500μm; step 2 reduces waste through material recycling, simultaneously provides carbon-carbon composite particles of two sizes, which are used for the preparation of the subsequent composite friction layer, play a toughening and reinforcing role, are helpful to improve the overall performance of the composite layer, and improve the material utilization rate;

[0047] Step 2.1, the carbon-carbon composite material is processed into a carbon-carbon brake disc according to the designed size, and the carbon-carbon brake disc is provided with a ventilation groove, a connecting flange and a mounting hole;

[0048] Step 2.2, the intermediate circular material head and the four corner material heads are reserved, and through coarse crushing, medium crushing and fine crushing to 100-500 μm, the material is sieved into small-size carbon-carbon composite material particles with a diameter of 100-300 μm and large-size carbon-carbon composite material particles with a diameter of 300-500 μm;

[0049] Step 3, preparation of the heat-conducting functional layer;

[0050] The heat-conducting mixed material is prepared according to a specific mass ratio, and the heat-conducting mixed material includes organic resin, curing agent, heat-conducting filler, large-size carbon-carbon composite material particles and silane coupling agent ethanol solution, the heat-conducting mixed material is heat-pressed and cured on the surface of the carbon-carbon brake disc to form the heat-conducting functional layer;

[0051] The mass ratio of the organic resin, the curing agent, the heat-conducting filler, the large-size carbon-carbon composite material particles and the silane coupling agent ethanol solution is 80-120:5-20:20-50:50-100:5-10 respectively; the organic resin and the curing agent cooperatively provide a matrix framework and form a firm structure through cross-linking reaction; the heat-conducting filler and the large-size carbon-carbon particles cooperatively form a high-efficiency heat-conducting path, which significantly improves the heat-dissipating capacity of the heat-conducting functional layer; the combination of the organic resin and the carbon-carbon particles enhances the structural strength, ensuring the stability and durability of the heat-conducting functional layer under high temperature and high load; the chemical bond between the silane coupling agent and the surface of the particles reduces the risk of interlayer separation, ensuring the firm combination of the heat-conducting functional layer and the carbon-carbon brake disc; the uniformity of the distribution of the resin matrix and the carbon-carbon particles effectively disperses stress, reduces the generation of cracks in the process of thermal cycling and prolongs the service life; the above-mentioned synergistic effects provide a guarantee for the stable operation of the brake disc under high temperature and high load;

[0052] Step 3.1, the organic resin, the curing agent, the heat-conducting filler, the large-size carbon-carbon composite material particles and the silane coupling agent ethanol solution are weighed according to the mass ratio of 100:8:45:70:7 respectively;

[0053] The organic resin is phenolic resin, the curing agent is urotropine, the solute of the silane coupling agent ethanol solution is aminopropyl triethoxysilane with a mass fraction of 1%, and the heat-conducting filler is a mixture of copper powder, mullite, diatomite, aluminum nitride and flaky carbon powder with a mass ratio of 7:15:13:5:5; in other embodiments, the solute of the silane coupling agent ethanol solution can also be one of alcohol silane and methyl vinyl silane; the heat-conducting filler can also be at least one of iron, iron alloy, aluminum, aluminum alloy, copper, copper alloy, aluminum oxide, silicon oxide, diatomite, silicon carbide, boron carbide, mullite, boron nitride, aluminum nitride and flaky carbon;

[0054] Step 3.2, first add large size carbon carbon composite particles and silane coupling agent ethanol solution, ball mill 0.5h; then add thermal conductive filler, continue to ball mill 1.5h; finally add organic resin and curing agent, ball mill 1h, to obtain thermal conductive mixture;

[0055] Step 3.3, hot-pressing curing the thermal conductive mixture on the surface of the carbon carbon brake disc to form a thermal conductive functional layer with a thickness of 2mm;

[0056] Wherein, the hot-pressing pressure is 3MPa, the curing temperature is 200℃, and the curing time is 1h; the hot-pressing promotes the formation of a continuous thermal conduction network in the internal material, greatly improves the heat dissipation efficiency of the thermal conductive functional layer, and reduces the brake heat accumulation; the thermal conductive functional layer after hot-pressing provides a basis for the composite friction layer, improves the bonding force between the composite friction layer and the carbon carbon brake disc, and prolongs the service life of the carbon ceramic brake disc with the composite friction layer; in addition, the hot-pressing reduces the porosity, improves the thermal fatigue resistance and thermal cycle stability of the thermal conductive functional layer, and ensures the performance reliability of the carbon ceramic brake disc with the composite friction layer in a high temperature environment;

[0057] Step 4, preparation of the composite friction layer;

[0058] According to a specific mass ratio, a friction mixture is prepared, which includes organic resin, curing agent, friction filler, small size carbon carbon composite particles, and silane coupling agent ethanol solution; the friction mixture is hot-pressing cured on the surface of the carbon carbon brake disc obtained in step 3 to form a composite friction layer; wherein the mass ratio of the organic resin, the curing agent, the friction filler, the small size carbon carbon composite particles, and the silane coupling agent ethanol solution is 80-120:5-20:20-50:40-80:4-8 respectively; the small size carbon carbon composite particles improve the mechanical properties and friction properties, which together with the friction filler reduce the heat accumulation during braking, and which combined with the organic resin ensure the structural uniformity and stability of the composite friction layer; the silane coupling agent is used to improve the interfacial bonding between the small size carbon carbon composite particles, the friction filler, and the organic resin:

[0059] Step 4.1, according to the mass ratio of 100:8:40:60:6, the organic resin, the curing agent, the friction filler, the small size carbon carbon composite particles, and the silane coupling agent ethanol solution are weighed respectively;

[0060] Wherein the organic resin is phenolic resin, the curing agent is urotropine, the solute of the silane coupling agent ethanol solution is aminopropyl triethoxysilane with a mass fraction of 1%; the friction filler is a mixture of copper powder, mullite, silicon carbide, and molybdenum disulfide with a mass ratio of 5:17:10:8; in other embodiments, the solute of the silane coupling agent ethanol solution can also use one of alcohol silane and methyl vinyl silane; the friction filler can use at least one of iron, copper, aluminum oxide, silicon oxide, silicon carbide, lead oxide, asbestos, mullite, graphite, boron nitride, and molybdenum disulfide;

[0061] Step 4.2, first add small size carbon carbon composite particles and silane coupling agent ethanol solution, ball mill for 0.5h; then add friction filler, continue to ball mill for 1h; finally add organic resin and curing agent, ball mill for 0.5h, to obtain the friction mixture;

[0062] Step 4.3, hot pressing and curing the friction mixture on the surface of the carbon carbon brake disc obtained in step 3 to form a composite friction layer with a thickness of 2mm;

[0063] Wherein, the hot pressing pressure is 3MPa, the curing temperature is 200°C, and the curing time is 1h; the hot pressing pressure and the curing temperature increase the reaction rate, ensure the density of the composite friction layer, and the hot pressing pressure promotes the close combination of the particles and the matrix, reduces the porosity, and enhances the strength and heat resistance of the composite friction layer;

[0064] Step 5, ceramization treatment;

[0065] Place the carbon carbon brake disc obtained in step 4 in a high temperature furnace for ceramization treatment, the temperature is 1600°C, and the time is 2h, to obtain a carbon ceramic brake disc with a density of 2.0g / cm 3 ;

[0066] The ceramization raw material for ceramization treatment is selected as silicon powder; in other embodiments, the ceramization raw material can be at least one of silicon powder, iron powder, copper powder, silicon-iron alloy powder, and copper-iron alloy powder;

[0067] Step 6, finishing;

[0068] Finish the carbon ceramic brake disc, clean the residual ceramization raw material at the connecting flange and mounting hole, and super-finish the friction surface to achieve the required surface finish and accuracy, to obtain a carbon ceramic brake disc with a composite friction layer.

[0069] Test according to SAE J2522-2014 "Ground Vehicle Global Brake Performance Bench Test Recommended Method", the caliper is a four-piston caliper, and the grinding sheet is PAGID-RSC1; the carbon ceramic brake disc with a composite friction layer obtained in Example 1 is used as the experimental group, and the carbon ceramic brake disc prepared by steps 1, 2, 5 and 6 in this embodiment without a friction layer is used as the control group;

[0070] Figure 1 、 Figure 2Figures 1 and 2 show the results of the test of the friction coefficient and the brake disc temperature variation for the experimental group and the control group, respectively, at the characteristic value 1 stage, with a braking pressure of 30 bar and a speed range of 80-30 km / h, indicating the measured friction performance during deceleration, with a starting temperature of 100°C; the average friction coefficient (Avg. μ) was 0.41 for both groups; the experimental group had a smaller range of fluctuation in the friction coefficient and the brake disc temperature during each deceleration cycle, indicating that its friction stability and thermal stability were superior to those of the control group. Figure 1 , Figure 2 The experimental group had a smaller range of fluctuation in the friction coefficient and the brake disc temperature during each deceleration cycle, indicating that its friction stability and thermal stability were superior to those of the control group.

[0071] Figure 3 , Figure 4 Figures 3 and 4 show the results of the test of the friction coefficient and the brake disc temperature variation for the experimental group and the control group, respectively, at the characteristic value 2 stage, with a braking pressure of 30 bar and a speed range of 80-30 km / h, indicating the measured friction performance during deceleration, with a starting temperature of 100°C; the average friction coefficient for the experimental group and the control group was 0.42 and 0.48, respectively; the control group had a higher initial friction coefficient at the characteristic value 2 stage, but this came at the expense of other performance (such as durability or resistance to thermal decay), and the friction coefficient curve for the experimental group was relatively smooth and had a smaller range of fluctuation, indicating better friction stability, and the brake disc temperature varied smoothly throughout the braking process without significant fluctuations.

[0072] Figure 5 , Figure 6 Figures 5 and 6 show the results of the test of the friction coefficient and the brake disc temperature variation for the experimental group and the control group, respectively, at the characteristic value 3 stage, with a braking pressure of 30 bar and a speed range of 80-30 km / h, indicating the measured friction performance during deceleration, with a starting temperature of 100°C; the average friction coefficient for the experimental group and the control group was 0.38 and 0.44, respectively; the experimental group exhibited higher friction performance consistency, making it suitable for application scenarios that require sustained high stability, and had better heat dissipation performance, which could delay the occurrence of thermal decay.

[0073] Figure 7 , Figure 8The test results of the friction coefficient change, brake disc braking temperature change and piston pressure value change (green) of the experimental group and the control group in the heat recession 1 stage, the initial temperature condition (T(I)) is 550°C, the deceleration (a) is 0.4g, and the speed range is from 100km / h to 5km / h; the average friction coefficients of the experimental group and the control group are 0.41 and 0.44 respectively, the minimum friction coefficients of the experimental group and the control group are 0.38 and 0.32 respectively, the friction coefficient of the experimental group is more stable, the heat dissipation performance is excellent, the heat recession resistance is stronger, and the experimental group can still maintain good friction performance and pressure stability in the high temperature stage, which is suitable for long time high frequency braking scene.

[0074] Example two

[0075] A preparation method of a carbon ceramic brake disc with a composite friction layer, comprising the following steps:

[0076] Step 1, preparation of carbon-carbon composite material;

[0077] A carbon matrix is deposited on a three-dimensional needled preform by a gas deposition method at a temperature of 800°C to obtain a carbon-carbon composite material with a density of 1.35g / cm 3 ;

[0078] The carbon source gas used for deposition is petroleum liquefied gas, and the carrier gas used is nitrogen;

[0079] Step 2, same as example one;

[0080] Step 3, preparation of heat conduction functional layer;

[0081] Step 3.1, organic resin, curing agent, heat conduction filler, large-size carbon-carbon composite particles and silane coupling agent ethanol solution are weighed according to the mass ratio of 80:8:25:60:6;

[0082] Among them, the organic resin is furan resin, the curing agent is dimethylbenzene sulfonic acid, and the solute of the silane coupling agent ethanol solution is phenylaminopropyltrimethoxysilane with a mass fraction of 1%;

[0083] The heat conduction filler is a mixture of metal powder and non-metal powder, specifically iron powder, aluminum oxide, silicon oxide and flake carbon powder with a mass ratio of 8:8:4:5;

[0084] Step 3.2, first add large-size carbon-carbon composite particles and silane coupling agent ethanol solution, and ball mill for 0.5h; then add heat conduction filler and continue to ball mill for 1h; finally add organic resin and curing agent and ball mill for 1h to obtain heat conduction mixture;

[0085] Step 3.3, heat pressing and curing the heat conduction mixture on the surface of the carbon-carbon brake disc to form a heat conduction functional layer with a thickness of 3mm;

[0086] The hot-pressing pressure is 4 MPa, the curing temperature is 200 DEG C, and the curing time is 2 h;

[0087] Step 4, composite friction layer preparation;

[0088] Step 4.1, organic resin, curing agent, friction filler, small-size carbon-carbon composite particles and silane coupling agent ethanol solution are weighed according to the mass ratio of 80:8:35:50:5 respectively;

[0089] The organic resin is phenolic resin, the curing agent is urotropine, the solute of the silane coupling agent ethanol solution is aminopropyl triethoxysilane, and the mass fraction is 1%;

[0090] The friction filler is a mixture of metal powder and non-metal powder, specifically iron powder, silicon carbide, lead oxide, mullite and graphite with a mass ratio of 5:12:7:10:8;

[0091] Step 4.2, first add small-size carbon-carbon composite particles and silane coupling agent ethanol solution, and ball mill for 0.5 h; then add friction filler, and continue to ball mill for 1 h; finally add organic resin and curing agent, and ball mill for 1 h to obtain friction mixture;

[0092] Step 4.3, the friction mixture is hot-pressed and cured on the surface of the carbon-carbon brake disc obtained in step 3 to form a composite friction layer with a thickness of 2 mm;

[0093] The hot-pressing pressure is 4 MPa, the curing temperature is 200 DEG C, and the curing time is 2 h;

[0094] Step 5, ceramic treatment;

[0095] The carbon-carbon brake disc obtained in step 4 is placed in a high-temperature furnace for ceramic treatment, the temperature is 1500 DEG C, and the time is 3 h, to obtain a carbon ceramic brake disc with a density of 2.1 g / cm 3 ;

[0096] The ceramic raw material for ceramic treatment is selected from silicon powder;

[0097] Step 6, same as example one.

[0098] Example three

[0099] A carbon ceramic brake disc with a composite friction layer preparation method, comprising the following steps:

[0100] Step 1, carbon-carbon composite material preparation;

[0101] A carbon matrix is deposited on a three-dimensional needle-punched preform by a gas deposition method at a temperature of 1050 DEG C, to obtain a carbon-carbon composite material with a density of 1.45 g / cm 3 ;

[0102] The carbon source gas used in the deposition is natural gas, and the carrier gas used is argon;

[0103] Step 2, same as Example 1;

[0104] Step 3, preparation of the heat-conducting functional layer;

[0105] Step 3.1, organic resin, curing agent, heat-conducting filler, large-size carbon-carbon composite particles, and silane coupling agent ethanol solution are weighed according to a mass ratio of 120:20:35:90:9;

[0106] Among them, the organic resin is furan resin, the curing agent is dimethylbenzene sulfonic acid, and the solute of the silane coupling agent ethanol solution is phenylaminopropyltrimethoxysilane with a mass fraction of 1%;

[0107] The heat-conducting filler is a mixture of aluminum nitride, aluminum oxide, diatomite, boron carbide, and flaky carbon powder with a mass ratio of 6:7:7:10:5;

[0108] Step 3.2, first, the large-size carbon-carbon composite particles and the silane coupling agent ethanol solution are added and ball-milled for 1 h; then, the heat-conducting filler is added and ball-milled for another 2 h; finally, the organic resin and the curing agent are added and ball-milled for 1 h, obtaining the heat-conducting mixture;

[0109] Step 3.3, the heat-conducting mixture is hot-pressed and cured on the surface of the carbon-carbon brake disc, forming a heat-conducting functional layer with a thickness of 2 mm;

[0110] Among them, the hot-pressing pressure is 2 MPa, the curing temperature is 150°C, and the curing time is 3 h;

[0111] Step 4, preparation of the composite friction layer;

[0112] Step 4.1, organic resin, curing agent, friction filler, small-size carbon-carbon composite particles, and silane coupling agent ethanol solution are weighed according to a mass ratio of 120:20:40:70:7;

[0113] Among them, the organic resin is phenol formaldehyde resin, the curing agent is urotropine, and the solute of the silane coupling agent ethanol solution is aminopropyltriethoxysilane with a mass fraction of 1%;

[0114] The friction filler is a mixture of silicon carbide, mullite, asbestos, graphite, and boron nitride with a mass ratio of 7:12:10:8:3;

[0115] Step 4.2, first, the small-size carbon-carbon composite particles and the silane coupling agent ethanol solution are added and ball-milled for 1 h; then, the friction filler is added and ball-milled for another 2 h; finally, the organic resin and the curing agent are added and ball-milled for 1 h, obtaining the friction mixture;

[0116] Step 4.3, hot-pressing and curing the friction mixture on the surface of the carbon-carbon brake disc obtained in step 3 to form a composite friction layer with a thickness of 1 mm;

[0117] wherein the hot-pressing pressure is 2 MPa, the curing temperature is 150°C, and the curing time is 3 h;

[0118] Step 5, ceramming treatment;

[0119] placing the carbon-carbon brake disc obtained in step 4 in a high-temperature furnace for ceramming treatment at a temperature of 1400°C for 3 h to obtain a carbon ceramic brake disc with a density of 2.4 g / cm 3 ;

[0120] The ceramming raw materials for the ceramming treatment are silicon powder and ferrosilicon alloy powder;

[0121] Step 6, same as in Example 1.

Claims

1. A method for manufacturing a carbon ceramic brake disc with a composite friction layer, characterized in that, It comprises the following steps: Step 1. Deposition of carbon matrix on a three-dimensional needled preform by vapor deposition method at a temperature of 600-1200 °C to obtain a carbon-carbon composite material having a density of 1.4 ± 0.05 g / cm 3 . Step 2, the carbon-carbon composite material is processed into a carbon-carbon brake disc, and residual material heads are sequentially subjected to crushing treatment to obtain small-size carbon-carbon composite particles with a diameter of 100-300 μm and large-size carbon-carbon composite particles with a diameter of 300-500 μm; Step 3, a heat-conducting mixture is prepared, the heat-conducting mixture comprises organic resin, curing agent, heat-conducting filler, large-size carbon-carbon composite particles, and silane coupling agent ethanol solution, and the mass ratio of the components is 80-120:5-20:20-50:50-100:5-10, the heat-conducting mixture is hot-pressed and cured on the surface of the carbon-carbon brake disc to form a heat-conducting functional layer, and the heat-conducting filler is at least one of aluminum, copper, boron nitride, aluminum nitride, and flaky carbon; Step 4, a friction mixture is prepared, the friction mixture comprises organic resin, curing agent, friction filler, small-size carbon-carbon composite particles, and silane coupling agent ethanol solution, and the mass ratio of the components is 80-120:5-20:20-50:40-80:4-8, the friction mixture is hot-pressed and cured on the surface of the carbon-carbon brake disc obtained in step 3 to form a composite friction layer, and the friction filler is at least one of silicon carbide, iron, copper, aluminum oxide, silicon oxide, lead oxide, asbestos, mullite, graphite, boron nitride, and molybdenum disulfide; Step 5, the carbon-carbon brake disc obtained in step 4 is placed in a high-temperature furnace for ceramization treatment at a temperature of 1200-1600℃ for 1-4h to obtain a carbon-ceramic brake disc with a density of 2.0-2.8g / cm 3 ​ Step 6, the carbon-tao brake disc is subjected to finishing processing, residual ceramicized raw materials are removed, and the friction surface is subjected to super-fine flat grinding to achieve the required surface smoothness and precision, thereby obtaining a carbon-tao brake disc with a composite friction layer.

2. The carbon-tao brake disc with a composite friction layer according to claim 1, characterized in that: In step 3, the heat-conducting mixture is prepared as follows: first, the large-size carbon-carbon composite particles and the silane coupling agent ethanol solution are added and ball-milled for 0.5-1 h; then, the heat-conducting filler is added and ball-milled for another 1-2 h; finally, the organic resin and the curing agent are added and ball-milled for 0.5-1 h, thereby obtaining the heat-conducting mixture; In step 4, the friction mixture is prepared as follows: first, the small-size carbon-carbon composite particles and the silane coupling agent ethanol solution are added and ball-milled for 0.5-1 h; then, the friction filler is added and ball-milled for another 1-2 h; finally, the organic resin and the curing agent are added and ball-milled for 0.5-1 h, thereby obtaining the friction mixture.

3. The carbon-tao brake disc with a composite friction layer according to claim 1, characterized in that: In steps 3 and 4, the organic resin is furan resin or phenolic resin, the curing agent is xylene sulfonic acid or urotropine, and the solute of the silane coupling agent ethanol solution is one of aminosilane, thiol silane, and methyl vinyl silane, and the mass fraction is 1%.

4. The carbon-tao brake disc with a composite friction layer according to any one of claims 1 to 3, characterized in that: In steps 3 and 4, the hot-pressing pressure of the hot-pressing and curing is 1-5 MPa, the curing temperature is 150-200℃, and the curing time is 1-3 h; In step 3, the thickness of the heat-conducting functional layer is 1-3 mm; In step 4, the thickness of the composite friction layer is 1-2 mm.

5. The method according to claim 4, wherein the ceramicized raw material in step 5 is at least one of silicon powder, iron powder, copper powder, silicon-iron alloy powder, and copper-iron alloy powder. The carbon ceramic brake disc with a composite friction layer is prepared by the method of claim 1.

6. A carbon-carbide brake disc with a composite friction layer, characterized in that: ​

Images