A highly wear-resistant and corrosion-resistant ceramic automobile brake disc and its preparation method

Abstract

The present invention relates to the technical field of brake disc materials, and in particular to a highly wear-resistant and rust-resistant ceramic automobile brake disc and a preparation method thereof. The highly wear-resistant and rust-resistant ceramic automobile brake disc is made of an aluminum-based composite substrate, a bonding metal and a ceramic, and is made by plasma spraying technology, and then combined with the organizational structure of a gradient coating to obtain a highly wear-resistant and rust-resistant ceramic automobile brake disc. By designing the ceramic coating and the aluminum-based composite substrate as a gradient integrated coating with a gradual change in composition, the thermal insulation and wear resistance of the ceramic coating can be achieved, and its good bonding ability with the substrate can be ensured, and the advantages of the metal bonding phase and the hard ceramic phase in the ceramic coating can be fully utilized. The ceramic coating has a strong bonding force with the aluminum-based composite substrate, and the adhesion is greatly improved. At the same time, the gradient integrated coating with a gradual change in composition forms a uniform and dense ceramic coating on the surface of the aluminum-based composite substrate, and the ceramic coating has high hardness and strong wear resistance.

Description

Technical Field

[0001] The present invention relates to the field of building technology, in particular to a highly wear-resistant and corrosion-resistant ceramic automobile brake disc and a preparation method thereof. Background Art

[0002] The technical foundation of metal ceramic coatings originates from the National 863 Major Project and has been successfully applied to a major national technical equipment (exhaust gas power generation equipment at a Sinopec Lanzhou refinery). The coating service life and performance of its generator smoke turbine blades surpass those of similar coatings in the United States. This type of coating can also be used for water-cooled wall tubes, reheat tubes, superheater tubes, and economizer tubes (commonly known as the "four tubes" of boilers) in thermal power plants and industrial boilers such as papermaking and chemical industries, as well as high-temperature resistant shaft sleeves, high-temperature valve sealing surfaces, and engine valve cores in the metallurgical and heavy chemical industries.

[0003] For example, Chinese patent application number CN202210785551.8 discloses a composite lightweight ceramic brake disc and its preparation method. Comprising a friction layer with high friction and wear performance and a structural layer with high-strength heat storage, the composite lightweight ceramic brake disc exhibits excellent overall performance, integrating product structural and functional characteristics. The friction layer has high density, low porosity, strong environmental adaptability, and excellent friction and wear performance, particularly for wet braking and high-kinetic energy braking, with minimal friction loss, excellent braking performance stability, and high thermal safety.

[0004] For example, Chinese patent application number CN202310403339.5 discloses a method for preparing a carbon-ceramic brake disc. The carbon-ceramic brake disc uses 4-phenyl-3-thiosemicarbazide-modified chopped carbon fibers as a mixed slurry component, and an injection molding process is used to prepare a brake disc blank. The carbon-ceramic brake disc obtained by carbonization, rough processing, and ceramicization has good bulk density, mechanical properties, thermal conductivity, and friction resistance. The present invention also uses 5-tert-butyl-2-methoxyaniline to modify the resin, which is then used in the preparation of the carbon-ceramic brake disc, so that the carbon-ceramic brake disc has better bulk density, mechanical properties, thermal conductivity, and friction resistance.

[0005] For example, the Chinese patent application number CN202310572574.5 discloses a composite process for carbon-ceramic brake discs with uniform ceramic composite carbon fibers. The present invention adopts FeSi75-modified C / C-SiC composite material to prepare carbon-ceramic brake discs with uniform ceramic composite carbon fibers; 2-decyltetradecane-p-mercaptoterephthalate is reacted with vinyl ferrocene, propenylsilsesquioxane, and sodium tert-butoxide to obtain a carbon fiber treating agent; the bundling and smoothness of the fiber bundles of the carbon fiber precursor are improved, and the infiltration effect of the C / C porous composite material and the FeSi75 alloy powder is improved, thereby improving the bending strength and fracture toughness of the carbon-ceramic brake disc.

[0006] When using the above technology, it was found that the following technical problems exist in the existing technology: the material of the commonly used thermal barrier coating is usually ceramic coating. By controlling the process, a high-hardness coating can be prepared, and the coating has excellent wear resistance. Therefore, it is possible to consider designing a ceramic coating of sufficient thickness to meet the thermal insulation function and achieve super wear resistance of the coating. However, the physical properties such as thermal expansion coefficient and hardness of a single ceramic coating of sufficient thickness are quite different from those of the substrate, resulting in excessive internal stress in the coating and failure during use. For this reason, we designed a highly wear-resistant and rust-resistant ceramic automobile brake disc and a preparation method thereof to provide another technical solution to the above technical problems. Summary of the Invention

[0007] Based on this, it is necessary to provide a highly wear-resistant and corrosion-resistant ceramic automobile brake disc and its preparation method to address the above technical problems. By designing the ceramic coating and the aluminum-based composite substrate into a gradient integrated coating with a gradual change in composition, the thermal insulation and wear resistance of the ceramic coating can be achieved, and its good bonding ability with the substrate can be ensured, and the advantages of the metal bonding phase and the hard ceramic phase in the coating can be fully utilized.

[0008] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0009] A highly wear-resistant and rust-resistant ceramic automobile brake disc and a preparation method thereof. The highly wear-resistant and rust-resistant ceramic automobile brake disc is made of an aluminum-based composite substrate, a bonding metal, and a ceramic by plasma spraying technology, and then combined with a gradient coating structure to produce a highly wear-resistant and rust-resistant ceramic automobile brake disc;

[0010] The preparation method of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc is as follows:

[0011] S1, preparing an aluminum-based composite substrate, wherein the aluminum-based composite substrate comprises 6% to 8% zinc, 1.5% to 2% copper, 2% to 6% magnesium, and the balance is aluminum, wherein a blank of the aluminum-based composite substrate is formed by mixing the above materials and smelting at a high temperature, and the aluminum-based composite substrate blank is formed by grinding and sandblasting the blank;

[0012] The temperature of the high temperature smelting is 900-1100°C;

[0013] S2, placing the aluminum-based composite substrate into the inert gas chamber of the ion sprayer, preheating the plasma spray gun to between 80 and 150° C., and controlling the temperature of the aluminum-based composite substrate at 200° C. during the spraying process;

[0014] S3, the ceramic spray powder comprises 12% to 18% aluminum oxide, 5% to 8% titanium oxide, 30% to 40% zirconium oxide, and the balance is chromium trioxide. The ceramic spray powder is formed by uniformly mixing the above materials. Under the action of high-pressure gas, the molten or semi-molten ceramic spray powder is sprayed at high speed onto the surface of the aluminum-based composite substrate. The ceramic spray powder is stacked together in a wavy manner on the surface of the aluminum-based composite substrate to form a gradient coating structure, forming a metal bonding layer;

[0015] S4, when the ceramic spray powder particle flow hits the metal bonding layer, it collides, deforms, solidifies and accumulates, thus forming a uniform, dense ceramic coating with high hardness and high wear resistance.

[0016] As a preferred embodiment of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc and its preparation method provided by the present invention, the aluminum-based composite substrate manufacturing steps in S1 are as follows: making a core mold, determining the shape and size of the brake disc by the core mold, pouring the composite aluminum liquid, pouring the composite aluminum liquid into the prepared core mold, and completing the production of the brake disc aluminum-based composite substrate blank after the composite aluminum liquid cools.

[0017] As a preferred embodiment of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc and the preparation method thereof provided by the present invention, the operating power of the S2 plasma spray gun is 20~35kW, while the power of the HEPJet high-performance supersonic spraying is 45~65kW.

[0018] As a preferred embodiment of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc and the preparation method thereof provided by the present invention, the spraying angle of the plasma spray gun in S2 is generally 60° to 80°.

[0019] As a preferred embodiment of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc and its preparation method provided by the present invention, the ceramic content of the metal bonding layer formed in S3 is higher than that of the aluminum alloy.

[0020] As a preferred embodiment of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc and its preparation method provided by the present invention, the ceramic spray powder material sprayed in S3 and the aluminum-based composite substrate will have a certain degree of mutual solubility, thereby enhancing the bonding strength between the coating and the substrate. The coating will undergo a transition process from liquid to solid, and finally tightly bonded to the metal substrate to form a bonding metal layer with the desired properties.

[0021] As a preferred embodiment of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc and the preparation method thereof provided by the present invention, the thickness of the ceramic coating formed in S4 is 2 mm.

[0022] As a preferred embodiment of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc and the preparation method thereof provided by the present invention, the microhardness of the ceramic coating in S4 is greater than HV1000.

[0023] It can be seen without a doubt that the above-mentioned technical solution of this application can definitely solve the technical problem to be solved by this application.

[0024] At the same time, through the above technical solutions, the present invention has at least the following beneficial effects:

[0025] The present invention provides a highly wear-resistant and corrosion-resistant ceramic automobile brake disc and a preparation method thereof. The ceramic coating and the aluminum-based composite substrate are designed to be a gradient integrated coating with a gradual change in composition. In this way, the thermal insulation and wear resistance of the ceramic coating can be achieved, and its good bonding ability with the substrate can be ensured. The advantages of the metal bonding phase and the hard ceramic phase in the ceramic coating are fully utilized. The ceramic coating has a strong bonding force with the aluminum-based composite substrate and the adhesion is greatly improved. At the same time, the gradient integrated coating with a gradual change in composition forms a uniform and dense ceramic coating on the surface of the aluminum-based composite substrate. The ceramic coating has high hardness and strong wear resistance.

[0026] The present invention provides a highly wear-resistant and corrosion-resistant ceramic automotive brake disc and its preparation method. By using plasma spraying technology, the heat generated during the coating process of the aluminum-based composite substrate is reduced, and the risk of deformation of the aluminum-based composite substrate during processing is reduced. In addition, since the parts are not electrically charged during the spraying process, the aluminum-based composite substrate is not easily damaged. This improves the hardness and wear resistance of the brake disc while also increasing the yield rate of the brake disc production.

[0027] The present invention provides a highly wear-resistant and corrosion-resistant ceramic automobile brake disc and a preparation method thereof. The brake disc substrate is made of an aluminum alloy, which is lighter in weight. The lighter brake disc can reduce the rotational inertia of the wheel and reduce the energy consumption of the vehicle, and has good heat dissipation performance. The aluminum alloy has excellent thermal conductivity and can effectively dissipate heat. During the braking process, the brake disc will generate a large amount of heat due to friction, and the aluminum alloy brake disc can quickly dissipate this heat to prevent performance degradation caused by high temperature. This ensures the stable operation of the brake system and extends the service life of the brake disc. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0029] Figure 1 This is a diagram of the design concept of the ceramic coating of the present invention; DETAILED DESCRIPTION

[0030] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0031] In order to enable those skilled in the art to better understand the solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0032] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features and technical solutions therein may be combined with each other.

[0033] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0034] Please refer to Figure 1 A highly wear-resistant and rust-resistant ceramic automobile brake disc and its preparation method. The highly wear-resistant and rust-resistant ceramic automobile brake disc is made of an aluminum-based composite substrate, a bonding metal, and a ceramic by plasma spraying technology, and then combined with a gradient coating structure to produce a highly wear-resistant and rust-resistant ceramic automobile brake disc;

[0035] The preparation method of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc is as follows:

[0036] Example 1, S1, preparing an aluminum-based composite substrate, the aluminum-based composite substrate comprising 6%-8% zinc, 1.5%-2% copper, 2%-6% magnesium, and the balance aluminum, the aluminum-based composite substrate blank being formed by mixing the above materials and smelting at a high temperature, and the aluminum-based composite substrate blank being formed by grinding and sandblasting.

[0037] The temperature of the high temperature smelting is 900-1100°C;

[0038] The steps for making the aluminum-based composite substrate in S1 are as follows: making a core mold, feeding the above materials into a high-temperature furnace in sequence, controlling the temperature to 1000° C. under the protection of nitrogen gas, and performing high-temperature smelting for 5 minutes to obtain aluminum-based composite aluminum liquid.

[0039] According to the design drawings and requirements of the brake disc, a precise core mold is made. The shape and size of the brake disc are determined by the core mold, and the composite aluminum liquid is poured into the prepared core mold. During the pouring process, it is necessary to ensure that the aluminum alloy melt evenly fills the core mold and avoid the generation of bubbles and inclusions to ensure the quality and performance of the brake disc. After pouring, it is cooled by air quenching. The cooling rate and temperature need to be controlled during the cooling and solidification process to avoid thermal stress and cracks. After the composite aluminum liquid is cooled, the production of the brake disc aluminum-based composite substrate blank is completed.

[0040] During the production of the aluminum-based composite substrate, arc-shaped keys and arc-shaped grooves are reserved on it. Through the design of structures such as arc-shaped keys and arc-shaped grooves, a metallurgical bond is achieved between the ceramic spray powder and the aluminum-based composite substrate, and an alloy transition layer is formed. This transition layer can effectively alleviate the physical property differences between different materials, enhance bonding strength, and improve the overall performance and stability of the brake disc.

[0041] The brake disc substrate is made of aluminum alloy. The density of aluminum alloy is much lower than that of traditional cast iron materials. Therefore, brake discs made of aluminum alloy are lighter, which effectively reduces the curb weight of the car, thereby improving fuel economy and vehicle handling performance. Lighter brake discs can also reduce the rotational inertia of the wheels, reduce vehicle energy consumption, and have good heat dissipation performance. Aluminum alloy has excellent thermal conductivity and can effectively dissipate heat. During the braking process, the brake disc will generate a lot of heat due to friction, and the aluminum alloy brake disc can quickly dissipate this heat to prevent performance degradation caused by high temperature, which ensures the stable operation of the braking system and extends the service life of the brake disc. It also has excellent corrosion resistance. Aluminum alloy has excellent corrosion resistance and can maintain stable performance in harsh environments. As a result, the brake disc with aluminum alloy as the base material has a longer service life and can reduce performance degradation and replacement frequency caused by corrosion.

[0042] Example 2, S2, in order to protect the particle beam during spraying, when coating the aluminum-based composite substrate, the aluminum-based composite substrate is first placed in the inert gas chamber of the ion sprayer, and the plasma spray gun is preheated between 80 and 150°C. During the spraying process, the temperature of the aluminum-based composite substrate needs to be controlled at 200°C. The aluminum-based composite substrate is heated to a certain temperature, which helps to improve the bonding strength between the coating and the substrate. Preheating can reduce the thermal stress between the substrate and the coating during the spraying process, thereby avoiding cracking or falling off of the coating.

[0043] In order to improve the thermal efficiency of the spray gun, the power of the S2 plasma spray gun is 20~35kW, while the power of the HEPJet high-performance supersonic spraying is 45~65kW.

[0044] In order to improve the quality of spraying, the spraying angle of the S2 plasma spray gun is usually 60° to 80°. When the spraying angle is too small, the fine powder particles of the ceramic spraying powder adhere to the spraying surface, hindering the continued spraying of the ceramic spraying powder particles, and forming a "bin" behind it, thereby forming a porous coating with irregular voids. Such voids not only weaken the strength of the coating, but also accumulate fine substances containing high oxides from the jet flow, changing the chemical composition of the coating.

[0045] When the spraying angle is less than 45°, a "shielding effect" of the spraying will occur, affecting the interlayer adhesion of the coating and reducing the bonding strength between the coating and the substrate.

[0046] During operation, after the aluminum-based composite substrate is placed in the inert gas chamber of the plasma processing equipment, the plasma gun muzzle is moved to a distance of 80-150 mm from the aluminum-based composite substrate to prevent the ceramic spraying powder from being heated too short and deforming insufficiently due to impact due to the spraying distance being too close, and the coating quality being affected. The rapid increase in the influence of the plasma flame flow and temperature will show severe oxidation, causing the coating to fall off. The spraying distance is prevented from being too far, and the powder heated to the molten state will be cooled when it contacts the part, and the flight speed will be reduced, affecting the coating quality and efficiency. Then, the plasma spray gun moved to the appropriate distance is adjusted to the appropriate angle, and the plasma spraying equipment is started to spray the aluminum-based composite substrate. The powder feeding process is set to 15-20 grams / minute to form a bonding metal layer on the aluminum-based composite substrate.

[0047] By using plasma spraying technology, the heat generated during the coating process on the aluminum-based composite substrate is reduced, minimizing the risk of deformation during processing. Furthermore, since the parts are not electrically charged during the spraying process, the aluminum-based composite substrate is less likely to be damaged. This improves the hardness and wear resistance of the brake disc while also increasing the yield rate of brake disc production. Furthermore, the high particle velocity and temperature during the plasma spraying process result in a low porosity coating and a high bonding strength with the substrate, making it less susceptible to coating peeling and cracking.

[0048] Example three, S3, before spraying, a composite powder with a particle size of generally -140 to +325 mesh is selected, and the powders that meet the purpose are mixed in the following proportions: the ceramic spray powder includes 12% to 18% aluminum oxide, 5% to 8% titanium oxide, 30% to 40% zirconium oxide, and the balance is chromium trioxide powder. The ceramic spray powder is formed by uniformly mixing the above materials. Then, plasma (i.e., excited and ionized gas) is used to activate the ceramic spray powder material. The plasma heats the spray material to a molten or semi-molten state through high-temperature, high-speed gas ions and electrons. The molten or semi-molten ceramic spray powder is sprayed at high speed onto the surface of the aluminum-based composite substrate under the action of high-pressure gas, and is stacked together in a wave-like manner on the surface of the aluminum-based composite substrate to form a gradient coating structure, form a metal bonding layer, and increase the density of the coating.

[0049] The ceramic content of the metal bonding layer formed in the S3 is higher than that of the aluminum alloy. The ceramic material has excellent wear resistance, high temperature resistance and a stable friction coefficient. These characteristics make the ceramic brake pad perform better during braking. When the ceramic content in the metal bonding layer is higher than that of the aluminum alloy, the hardness and wear resistance of the brake disc can be significantly improved, thereby extending the service life of the brake disc. In addition, the high-temperature stability of the ceramic material helps to reduce thermal degradation during braking and maintain a stable braking effect.

[0050] The ceramic spray powder material sprayed in S3 will melt to a certain extent with the aluminum-based composite substrate, thereby enhancing the bonding strength between the coating and the substrate. The coating will undergo a transformation process from liquid to solid, and finally tightly bond with the metal substrate to form a bonding metal layer with the desired properties.

[0051] During operation, 12% to 18% aluminum oxide, 5% to 8% titanium oxide, 30% to 40% zirconium oxide, and the balance chromium trioxide are placed into a blender and the time is set to 30 minutes to obtain ceramic spray powder. In the process of forming the gradient coating, the composition of the spraying material is adjusted. When the ceramic spray powder material is sprayed on the surface of the aluminum-based composite substrate through a plasma spray gun, the aluminum oxide, titanium oxide, zirconium oxide and chromium trioxide in the ceramic spray powder material are coated with zinc, copper, magnesium and aluminum in the aluminum-based composite substrate. The organizational structure of the gradient coating is reflected. In the ceramic gradient coating, as the coating thickness increases, the content of the ceramic phase component gradually increases, while the content of the metal phase component decreases accordingly. This gradient distribution makes it possible to have no obvious interface between the metal phase and the ceramic phase coating, thereby effectively solving the problem of mismatched performance between the two, weakening or eliminating the stress in the coating to the greatest extent, and improving the bonding strength between the coating and the substrate.

[0052] Spraying parameters (such as spray current, spray distance, powder feed rate, etc.), as well as the number of spray layers and the composition changes between each layer, are used to achieve a smooth transition from one coating material to another, thereby forming a coating with the desired property gradient. This gradient coating can significantly improve the wear resistance, corrosion resistance, and heat resistance of brake discs, extending their service life.

[0053] By designing the ceramic coating and the aluminum-based composite substrate into a gradient integrated coating with a gradual change in composition, the thermal insulation and wear resistance of the ceramic coating can be achieved, and its good bonding ability with the substrate can be guaranteed. The advantages of the metal bonding phase and the hard ceramic phase in the ceramic coating can be fully utilized. The ceramic coating has a strong bonding force with the aluminum-based composite substrate and the adhesion is greatly improved. At the same time, the gradient integrated coating with a gradual change in composition forms a uniform and dense ceramic coating on the surface of the aluminum-based composite substrate. The ceramic coating has high hardness and strong wear resistance.

[0054] Example 4, S4, in order to facilitate the formation of a ceramic coating with uniform thickness outside the bonding metal layer, when the ceramic spray powder particle flow hits the metal bonding layer, it will collide, deform, solidify and accumulate, thereby forming a uniform, dense ceramic coating with high hardness and high wear resistance.

[0055] In order to give full play to the advantages of the metal bonding phase and the hard ceramic phase in the coating, the thickness of the ceramic coating formed in S4 is 2 mm.

[0056] During operation, after a ceramic coating with a thickness of 2 mm is formed outside the bonding metal layer, the preparation of a highly wear-resistant and corrosion-resistant ceramic automobile brake disc is completed.

[0057] The microhardness of the ceramic coating in S4 is greater than HV1000, and the coating has excellent wear resistance. Therefore, it is possible to consider designing a ceramic coating with sufficient thickness to meet the heat insulation function and achieve super wear resistance of the coating.

[0058] The present invention provides a method for preparing a highly wear-resistant and corrosion-resistant ceramic automobile brake disc as follows: a worker sequentially feeds a mixed metal of 6%-8% zinc, 1.5%-2% copper, 2%-6% magnesium, and the remainder aluminum into a high-temperature furnace, controls the temperature at 1000°C under the protection of nitrogen gas, and performs high-temperature sintering for 5 minutes to obtain aluminum-based composite aluminum liquid. During the preparation process of the aluminum-based composite substrate, arc keys and arc grooves need to be reserved on it. By designing structures such as the arc keys and arc grooves, the ceramic spray powder and the aluminum-based composite substrate are To achieve the effect of metallurgical bonding between the materials, before spraying, a composite powder with a particle size of generally -140 to +325 mesh is selected, and the powders that meet the purpose are mixed in the following proportions: ceramic spray powder includes 12% to 18% of aluminum oxide, 5% to 8% of titanium oxide, 30% to 40% of zirconium oxide, and the balance is chromium trioxide. The ceramic spray powder is uniformly mixed with the above materials. After the mixing is completed, the aluminum-based composite substrate is placed in the inert gas chamber of the ion spray machine, and the plasma spray gun is preheated by The temperature is between 80 and 150°C. In order to improve the quality of spraying, the spraying angle of the plasma spray gun in S2 is generally 60° to 80°. By moving the plasma gun muzzle to a length of 80-150 mm from the aluminum-based composite substrate, the powder feeding process is set to 15-20 g / min, and then the aluminum-based composite substrate is sprayed. When the ceramic spray powder material is sprayed on the surface of the aluminum-based composite substrate through the plasma spray gun, the aluminum oxide, titanium oxide, zirconium oxide and chromium trioxide in the ceramic spray powder material react with the zinc, copper, magnesium and aluminum in the aluminum-based composite substrate to form a gradient coating structure. In the ceramic coating gradient coating, as the coating thickness increases, the content of the ceramic phase component gradually increases, while the content of the metal phase component decreases accordingly. When the ceramic spray powder particle flow collides with the metal bonding layer, it collides, deforms, solidifies and accumulates, thereby forming a uniform, dense ceramic coating with high hardness and high wear resistance. When a ceramic coating with a thickness of 2 mm is formed outside the bonding metal layer, the preparation of a high-wear-resistant and rust-resistant ceramic automobile brake disc is completed.

[0059] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. The preferred embodiments do not describe all details in detail, nor do they limit the present invention to the specific embodiments described. Obviously, many modifications and variations are possible based on the contents of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A method for preparing a highly wear-resistant and corrosion-resistant ceramic automobile brake disc, characterized in that: The highly wear-resistant and rust-resistant ceramic automobile brake disc is made of an aluminum-based composite substrate, a bonding metal and ceramic spray powder through plasma spraying technology, and is combined with a gradient coating structure to produce a highly wear-resistant and rust-resistant ceramic automobile brake disc; The preparation method of the highly wear-resistant and corrosion-resistant ceramic automobile brake disc is as follows: S1, preparing an aluminum-based composite substrate, wherein the aluminum-based composite substrate comprises 6% to 8% zinc, 1.5% to 2% copper, 2% to 6% magnesium, and the balance is aluminum, wherein a blank of the aluminum-based composite substrate is formed by mixing the above materials and smelting at a high temperature, and the aluminum-based composite substrate blank is formed by grinding and sandblasting the blank; The temperature of the high temperature smelting is 900-1100°C; S2, placing the aluminum-based composite substrate into the inert gas chamber of the ion sprayer, preheating the plasma spray gun to between 80 and 150° C., and controlling the temperature of the aluminum-based composite substrate at 200° C. during the spraying process; S3, the ceramic spray powder includes 12% to 18% aluminum oxide, 5% to 8% titanium oxide, 30% to 40% zirconium oxide, and the balance is chromium trioxide. The ceramic spray powder is formed by uniformly mixing the above materials. Under the action of high-pressure gas, the molten or semi-molten ceramic spray powder is sprayed at high speed onto the surface of the aluminum-based composite substrate. The ceramic spray powder is stacked together in a wavy manner on the surface of the aluminum-based composite substrate to form a gradient coating structure, forming a metal bonding layer. The ceramic content of the metal bonding layer is higher than that of the aluminum alloy; S4, when the ceramic spray powder particle flow hits the metal bonding layer, it collides, deforms, solidifies and accumulates, thus forming a uniform, dense ceramic coating with high hardness and high wear resistance.

2. The method for preparing a highly wear-resistant and corrosion-resistant ceramic automobile brake disc according to claim 1, characterized in that: The steps for making the aluminum-based composite substrate in S1 are as follows: making a core mold, determining the shape and size of the brake disc through the core mold, pouring the composite aluminum liquid, pouring the composite aluminum liquid into the prepared core mold, and completing the production of the brake disc aluminum-based composite substrate blank after the composite aluminum liquid cools.

3. The method for preparing a highly wear-resistant and corrosion-resistant ceramic automobile brake disc according to claim 1, characterized in that: The operating power of the plasma spray gun in S2 is 20~35kW.

4. The method for preparing a highly wear-resistant and corrosion-resistant ceramic automobile brake disc according to claim 1, characterized in that: The spraying angle of the plasma spray gun in the S2 is 60° to 80°.

5. The method for preparing a highly wear-resistant and corrosion-resistant ceramic automobile brake disc according to claim 1, characterized in that: The ceramic spray powder material sprayed in S3 will melt to a certain extent with the aluminum-based composite substrate, thereby enhancing the bonding strength between the coating and the substrate. The coating will undergo a transformation process from liquid to solid, and finally tightly bond with the metal substrate to form a bonding metal layer with the desired properties.

6. The method for preparing a highly wear-resistant and corrosion-resistant ceramic automobile brake disc according to claim 1, characterized in that: The thickness of the ceramic coating formed in S4 is 2 mm.

7. The method for preparing a highly wear-resistant and corrosion-resistant ceramic automobile brake disc according to claim 1, characterized in that: The microhardness of the ceramic coating in S4 is greater than HV1000.

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