Preparation method of high wear-resistant ceramic-based composite brake disc

Abstract

This invention discloses a method for preparing a highly wear-resistant ceramic-based composite brake disc, relating to the technical field of automotive brake system materials. The method includes preparing a three-dimensional ceramic skeleton, preparing a ceramic slurry, impregnating the skeleton with the ceramic slurry to form a ceramic preform, and then composite-molding the preform with a lightweight alloy substrate. The resulting brake disc exhibits excellent wear resistance, heat resistance, and structural strength, making it suitable for use in the braking systems of high-performance vehicles.

Description

Technical Field

[0001] The invention relates to the technical field of automobile brake system materials, in particular to a method for preparing a high-wear-resistant ceramic-based composite brake disc. Background Art

[0002] With the rapid development of the automotive industry, vehicle speeds and load capacities are constantly increasing, placing higher demands on braking system performance. As a key component of the braking system, the performance of brake discs directly impacts vehicle safety and reliability. Currently, widely used brake discs are primarily made of gray cast iron, which offers excellent thermal conductivity and processability. However, these materials suffer from drawbacks such as heavy weight, poor wear resistance, and susceptibility to rust, making them difficult to meet the lightweight and high-wear resistance requirements of high-performance vehicles.

[0003] To overcome the shortcomings of traditional gray cast iron brake discs, researchers have developed a variety of new materials and preparation methods. For example, aluminum-based composites have attracted attention due to their light weight and high thermal conductivity, but their wear resistance and high-temperature performance still need to be improved. Ceramic-based composites are considered an ideal brake disc material due to their excellent wear resistance and high-temperature stability. However, the brittleness and high processing difficulty of ceramic materials limit their application in brake discs.

[0004] In recent years, researchers have attempted to combine ceramics with metals to achieve a balance between the wear resistance of ceramics and the toughness of metals. For example, the use of ceramic particle-reinforced aluminum-based composites improves the wear resistance and high-temperature performance of the material by introducing ceramic particles into the aluminum alloy. However, this approach suffers from problems such as uneven distribution of ceramic particles and poor interfacial bonding, which compromises the overall performance of the composite.

[0005] Research on three-dimensional ceramic skeleton-reinforced metal-matrix composites has also made some progress. This method creates a three-dimensional ceramic skeleton and combines it with a metal matrix to form a composite material with excellent mechanical properties and wear resistance. However, the existing preparation process is complex and costly, making large-scale industrial production difficult.

[0006] In summary, the existing technology has achieved certain results in improving the performance of brake discs, but there are still problems such as uneven material properties, complex preparation process, and high cost. It is difficult to meet the comprehensive requirements of high-performance vehicles for lightweight brake discs, high wear resistance and high-temperature stability.

[0007] Therefore, developing a preparation method for a highly wear-resistant ceramic-based composite brake disc with simple preparation process, low cost and excellent performance has important practical significance and application value. Summary of the Invention

[0008] The present invention aims to provide a method for preparing a highly wear-resistant ceramic-based composite brake disc. This method features simple manufacturing processes, low cost, and excellent performance, making it suitable for industrial production. The method comprises the steps of preparing a three-dimensional ceramic skeleton, preparing a ceramic slurry, impregnating the skeleton with the ceramic slurry to form a ceramic preform, and then composite-molding the preform with a lightweight alloy substrate.

[0009] The method for preparing the highly wear-resistant ceramic-based composite brake disc of the present invention comprises the following steps:

[0010] 1) Preparation of three-dimensional ceramic skeleton:

[0011] Cut the polyurethane foam into the desired shape, immerse it in ceramic slurry, dry it, and sinter it at high temperature for 1-3 hours to obtain a three-dimensional ceramic skeleton;

[0012] 2) Preparation of ceramic slurry:

[0013] Mix the raw materials in the following mass proportions and stir evenly to obtain ceramic slurry:

[0014] Alumina powder: 50-70 parts

[0015] Silicon carbide powder: 20-30 parts

[0016] Kaolin: 10-20 parts

[0017] Binder: 2 to 6 parts

[0018] Deionized water: 125-160 parts

[0019] 3) Forming a ceramic preform:

[0020] The ceramic slurry is impregnated into a three-dimensional ceramic skeleton, dried, and sintered for 1-2 hours to form a ceramic preform;

[0021] 4) Composite molding:

[0022] The ceramic preform is placed in a mold, and a molten light alloy matrix is ​​injected into the preform using a vacuum pressure infiltration process. After cooling, the preform is demoulded to obtain a ceramic-based composite brake disc.

[0023] In the step 2), the binder is prepared by reacting bismaleimide, 7-amino-2H-1,4-benzoxazine-3(4H)-one, triethanolamine, mercapto-β-cyclodextrin, and benzoyl peroxide.

[0024] Furthermore, the sintering temperature in step 1) is 1150-1250°C.

[0025] Furthermore, the preparation method of the binder in step 2) is as follows:

[0026] By weight, 36-72 parts of bismaleimide and 10-20 parts of 7-amino-2H-1,4-benzoxazin-3(4H)-one (CAS: 26215-14-5) are added with 0.5-2 parts of triethanolamine catalyst, and melt-mixed at 160-170°C for 1-3 hours. The mixture is then cooled to 100-110°C, 1-3 parts of mercapto-β-cyclodextrin and 1-3 parts of benzoyl peroxide are added, ultrasonically dispersed for 30-100 minutes, and stirred for 2-4 hours to form a high-temperature resistant adhesive, i.e., the desired binder.

[0027] Furthermore, the sintering temperature in step 3) is 1200-1350°C.

[0028] Furthermore, in step 4), the lightweight alloy matrix is ​​an aluminum alloy.

[0029] Furthermore, the vacuum pressure infiltration process parameters in step 4) are:

[0030] Vacuum degree: -0.09 MPa

[0031] Impregnation temperature: 700~750℃

[0032] Immersion time: 10 to 15 minutes.

[0033] Beneficial Effects: 1. By introducing high-hardness aluminum oxide and silicon carbide particles into the ceramic slurry, a dense ceramic preform is formed, enhancing the surface hardness and wear resistance of the brake disc. In addition, the three-dimensional ceramic skeleton structure provides excellent support, reducing brake disc wear during braking.

[0034] 2. Ceramic materials inherently possess excellent high-temperature resistance. The addition of kaolin to the ceramic preform enhances the material's thermal stability. Furthermore, a vacuum pressure infiltration process is used to inject molten aluminum alloy into the ceramic preform, creating a dense composite structure that further enhances the brake disc's heat resistance.

[0035] 3. The use of lightweight aluminum alloy as the base material replaces traditional gray cast iron, significantly reducing the overall weight of the brake disc. In addition, the high porosity structure of the three-dimensional ceramic skeleton further reduces the weight of the brake disc while ensuring strength.

[0036] 4. The addition of binder is to improve the bonding force between ceramic particles. The bismaleimide, 7-amino-2H-1,4-benzoxazine-3(4H)-one and other components in the binder undergo polymerization reaction at high temperature to form a high molecular polymer network, which firmly bonds the ceramic particles together and ensures that the ceramic slurry maintains a stable structure during the molding and sintering process, laying the foundation for the subsequent formation of a uniform and dense ceramic preform. DETAILED DESCRIPTION

[0037] In order to more clearly understand the above-mentioned objectives, features and advantages of the present invention, the scheme of the present invention will be further described below. It should be noted that, in the absence of conflict, the embodiments of the present invention and the features therein can be combined with each other.

[0038] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein; the embodiments in the specification are only some embodiments of the present invention, rather than all embodiments.

[0039] Example 1: A method for preparing a highly wear-resistant ceramic-based composite brake disc, comprising the following steps:

[0040] 1) Preparation of three-dimensional ceramic skeleton

[0041] The polyurethane foam is cut into the desired shape, immersed in ceramic slurry, dried and sintered at 1200°C for 2 hours to obtain a three-dimensional ceramic skeleton.

[0042] 2) Preparation of ceramic slurry

[0043] Mix raw materials by mass:

[0044] Alumina powder: 60 kg

[0045] Silicon carbide powder: 25 kg

[0046] Kaolin: 15 kg

[0047] Binder: 2 kg (Preparation method: 54 kg of bismaleimide and 15 kg of 7-amino-2H-1,4-benzoxazin-3(4H)-one were added with 1 kg of triethanolamine catalyst and melt-mixed at 165°C for 2 hours; then the mixture was cooled to 105°C and 2 kg of mercapto-β-cyclodextrin and 2 kg of benzoyl peroxide were added. The mixture was ultrasonically dispersed for 60 minutes and stirred for 3 hours.)

[0048] Deionized water: 140 kg

[0049] Stir evenly to obtain ceramic slurry.

[0050] 3) Forming a ceramic preform

[0051] The ceramic slurry was impregnated into a three-dimensional ceramic skeleton, dried, and then sintered at 1250° C. for 1.5 hours to form a ceramic preform.

[0052] 4) Composite molding

[0053] The ceramic preform is placed in a mold and infiltrated at 725°C for 12 minutes using a vacuum pressure infiltration process (vacuum degree: -0.09 MPa). Molten aluminum alloy is injected into the preform and demolded after cooling to obtain a ceramic-based composite brake disc.

[0054] Example 2: A method for preparing a highly wear-resistant ceramic-based composite brake disc, comprising the following steps:

[0055] 1) Preparation of three-dimensional ceramic skeleton

[0056] The polyurethane foam is cut into the desired shape, immersed in the ceramic slurry, dried and sintered at 1150°C for 1 hour to obtain a three-dimensional ceramic skeleton.

[0057] 2) Preparation of ceramic slurry

[0058] Mix raw materials by mass:

[0059] Alumina powder: 50 kg

[0060] Silicon carbide powder: 20 kg

[0061] Kaolin: 10 kg

[0062] Binder: 3.5 kg (Preparation method: 36 kg of bismaleimide and 10 kg of 7-amino-2H-1,4-benzoxazin-3(4H)-one were added with 0.5 kg of triethanolamine catalyst and melt-mixed at 160°C for 1 hour; then cooled to 100°C, 1 kg of mercapto-β-cyclodextrin and 1 kg of benzoyl peroxide were added, ultrasonically dispersed for 30 minutes, and stirred for 2 hours)

[0063] Deionized water: 125 kg

[0064] Stir evenly to obtain ceramic slurry.

[0065] 3) Forming a ceramic preform

[0066] The ceramic slurry is impregnated into a three-dimensional ceramic skeleton, dried, and then sintered at 1200° C. for 1 hour to form a ceramic preform.

[0067] 4) Composite molding

[0068] The ceramic preform is placed in a mold and infiltrated at 700°C for 10 minutes using a vacuum pressure infiltration process (vacuum degree: -0.09 MPa). Molten aluminum alloy is injected into the preform and demolded after cooling to obtain a ceramic-based composite brake disc.

[0069] Example 3: A method for preparing a highly wear-resistant ceramic-based composite brake disc, comprising the following steps:

[0070] 1) Preparation of three-dimensional ceramic skeleton

[0071] The polyurethane foam is cut into the desired shape, immersed in the ceramic slurry, dried and sintered at 1250°C for 3 hours to obtain a three-dimensional ceramic skeleton.

[0072] 2) Preparation of ceramic slurry

[0073] Mix raw materials by mass:

[0074] Alumina powder: 70 kg

[0075] Silicon carbide powder: 30 kg

[0076] Kaolin: 20 kg

[0077] Binder: 5 kg (Preparation method: 72 kg of bismaleimide and 20 kg of 7-amino-2H-1,4-benzoxazin-3(4H)-one were added with 2 kg of triethanolamine catalyst and melt-mixed at 170°C for 3 hours; then cooled to 110°C, 3 kg of mercapto-β-cyclodextrin and 3 kg of benzoyl peroxide were added, and ultrasonic dispersion was performed for 100 minutes, followed by stirring for 4 hours)

[0078] Deionized water: 160 kg

[0079] Stir evenly to obtain ceramic slurry.

[0080] 3) Forming a ceramic preform

[0081] The ceramic slurry is impregnated into a three-dimensional ceramic skeleton, dried, and then sintered at 1350° C. for 2 hours to form a ceramic preform.

[0082] 4) Composite molding

[0083] The ceramic preform is placed in a mold and infiltrated at 750°C for 15 minutes using a vacuum pressure infiltration process (vacuum degree: -0.09 MPa). Molten aluminum alloy is injected into the preform and demolded after cooling to obtain a ceramic-based composite brake disc.

[0084] Example 4: A method for preparing a highly wear-resistant ceramic-based composite brake disc, comprising the following steps:

[0085] 1) Preparation of three-dimensional ceramic skeleton

[0086] The polyurethane foam is cut into the desired shape, immersed in the ceramic slurry, dried and sintered at 1220°C for 2 hours to obtain a three-dimensional ceramic skeleton.

[0087] 2) Preparation of ceramic slurry

[0088] Mix raw materials by mass:

[0089] Alumina powder: 65 kg

[0090] Silicon carbide powder: 28 kg

[0091] Kaolin: 18 kg

[0092] Binder: 6 kg (Preparation method: 60 kg of bismaleimide and 18 kg of 7-amino-2H-1,4-benzoxazin-3(4H)-one were added with 1.5 kg of triethanolamine catalyst and melt-mixed at 168°C for 2.5 hours. The mixture was cooled to 108°C and 2 kg of mercapto-β-cyclodextrin and 2 kg of benzoyl peroxide were added. The mixture was ultrasonically dispersed for 80 minutes and stirred for 3.5 hours.)

[0093] Deionized water: 150 kg

[0094] Stir evenly to obtain ceramic slurry.

[0095] 3) Forming a ceramic preform

[0096] The ceramic slurry was impregnated into a three-dimensional ceramic skeleton, dried, and then sintered at 1300° C. for 1.5 hours to form a ceramic preform.

[0097] 4) Composite molding

[0098] The ceramic preform was placed in a mold and infiltrated at 730°C for 13 minutes using a vacuum pressure infiltration process (vacuum degree: -0.09 MPa). Molten aluminum alloy was injected into the preform and demolded after cooling to obtain a ceramic-based composite brake disc.

[0099] Comparative Example 1: A method for preparing a highly wear-resistant ceramic-based composite brake disc, comprising the following steps:

[0100] 1) Preparation of three-dimensional ceramic skeleton

[0101] The polyurethane foam is cut into the desired shape, immersed in ceramic slurry, dried and sintered at 1200°C for 2 hours to obtain a three-dimensional ceramic skeleton.

[0102] 2) Preparation of ceramic slurry

[0103] Mix raw materials by mass:

[0104] Alumina powder: 60 kg

[0105] Silicon carbide powder: 25 kg

[0106] Kaolin: 15 kg

[0107] Binder: 2 kg (Preparation method: Add 15 kg of 7-amino-2H-1,4-benzoxazin-3(4H)-one to 1 kg of triethanolamine catalyst and melt mix at 165°C for 2 hours; cool to 105°C, add 2 kg of mercapto-β-cyclodextrin and 2 kg of benzoyl peroxide, ultrasonically disperse for 60 minutes, and stir for 3 hours)

[0108] Deionized water: 140 kg

[0109] Stir evenly to obtain ceramic slurry.

[0110] 3) Forming a ceramic preform

[0111] The ceramic slurry was impregnated into a three-dimensional ceramic skeleton, dried, and then sintered at 1250° C. for 1.5 hours to form a ceramic preform.

[0112] 4) Composite molding

[0113] The ceramic preform is placed in a mold and infiltrated at 725°C for 12 minutes using a vacuum pressure infiltration process (vacuum degree: -0.09 MPa). Molten aluminum alloy is injected into the preform and demolded after cooling to obtain a ceramic-based composite brake disc.

[0114] Comparative Example 2: A method for preparing a highly wear-resistant ceramic-based composite brake disc, comprising the following steps:

[0115] 1) Preparation of three-dimensional ceramic skeleton

[0116] The polyurethane foam is cut into the desired shape, immersed in ceramic slurry, dried and sintered at 1200°C for 2 hours to obtain a three-dimensional ceramic skeleton.

[0117] 2) Preparation of ceramic slurry

[0118] Mix raw materials by mass:

[0119] Alumina powder: 60 kg

[0120] Silicon carbide powder: 25 kg

[0121] Kaolin: 15 kg

[0122] Binder: 2 kg (Preparation method: Add 54 kg of bismaleimide to 1 kg of triethanolamine catalyst and melt mix at 165°C for 2 hours; cool to 105°C, add 2 kg of mercapto-β-cyclodextrin and 2 kg of benzoyl peroxide, ultrasonically disperse for 60 minutes, and stir for 3 hours)

[0123] Deionized water: 140 kg

[0124] Stir evenly to obtain ceramic slurry.

[0125] 3) Forming a ceramic preform

[0126] The ceramic slurry was impregnated into a three-dimensional ceramic skeleton, dried, and then sintered at 1250° C. for 1.5 hours to form a ceramic preform.

[0127] 4) Composite molding

[0128] The ceramic preform is placed in a mold and infiltrated at 725°C for 12 minutes using a vacuum pressure infiltration process (vacuum degree: -0.09 MPa). Molten aluminum alloy is injected into the preform and demolded after cooling to obtain a ceramic-based composite brake disc.

[0129] Test Method

[0130] To fully evaluate the performance of brake discs, the following standardized test methods are used:

[0131] 1) Wear resistance test:

[0132] Equipment: MMW-1F weight-loaded friction and wear testing machine (compliant with ASTM G99-05 standard).

[0133] Parameters: load 50N, speed 200r / min, test time 30 minutes, temperature 25℃.

[0134] Evaluation index: Wear rate (mg / (N・m)) = wear mass loss / (load × friction distance).

[0135] 2) Mechanical properties test:

[0136] Bending strength test:

[0137] Equipment: Electronic universal testing machine (conforming to ASTM C1161-13 standard).

[0138] Parameters: three-point bending test, span 40 mm, loading speed 0.5 mm / min.

[0139] Impact toughness test:

[0140] Equipment: Pendulum impact testing machine, test temperature 25℃.

[0141] Table 1: Test results of various embodiments and comparative examples

[0142]

[0143] The above test data show that the embodiments of the present invention have reached or exceeded the level of existing high-end ceramic brake discs in terms of key performance indicators, and have achieved optimization of comprehensive performance through innovations in material formulation and structural design.

[0144] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A method for preparing a highly wear-resistant ceramic-based composite brake disc, characterized in that: The following steps are involved: 1) Preparation of three-dimensional ceramic skeleton: Cut the polyurethane foam into the desired shape, immerse it in ceramic slurry, dry it, and sinter it at high temperature for 1-3 hours to obtain a three-dimensional ceramic skeleton; 2) Preparation of ceramic slurry: Mix the raw materials in the following mass proportions and stir evenly to obtain ceramic slurry: Alumina powder: 50-70 parts Silicon carbide powder: 20-30 parts Kaolin: 10-20 parts Binder: 2 to 6 parts Deionized water: 125-160 parts 3) Forming a ceramic preform: The ceramic slurry is impregnated into a three-dimensional ceramic skeleton, dried, and sintered for 1-2 hours to form a ceramic preform; 4) Composite molding: The ceramic preform is placed in a mold, and a molten light alloy matrix is ​​injected into the preform using a vacuum pressure infiltration process. After cooling, the preform is demoulded to obtain a ceramic-based composite brake disc. In step 2), the binder is prepared by reacting bismaleimide, 7-amino-2H-1,4-benzoxazine-3(4H)-one, triethanolamine, mercapto-β-cyclodextrin, and benzoyl peroxide; The preparation method of the binder in step 2) is as follows: By weight, 36-72 parts of bismaleimide and 10-20 parts of 7-amino-2H-1,4-benzoxazin-3(4H)-one are added with 0.5-2 parts of triethanolamine catalyst, and melt-mixed at 160-170° C. for 1-3 hours; then the temperature is lowered to 100-110° C., 1-3 parts of mercapto-β-cyclodextrin and 1-3 parts of benzoyl peroxide are added, ultrasonically dispersed for 30-100 minutes, and then stirred for 2-4 hours to form a high-temperature resistant adhesive, i.e., the desired binder.

2. The method for preparing a highly wear-resistant ceramic-based composite brake disc according to claim 1, characterized in that: The sintering temperature in step 1) is 1150-1250°C.

3. The method for preparing a highly wear-resistant ceramic-based composite brake disc according to claim 1, characterized in that: The sintering temperature in step 3) is 1200-1350°C.

4. The method for preparing a highly wear-resistant ceramic-based composite brake disc according to claim 1, wherein: In the step 4), the light alloy matrix is ​​an aluminum alloy.

5. The method for preparing a highly wear-resistant ceramic-based composite brake disc according to claim 1, characterized in that: The vacuum pressure infiltration process parameters in step 4) are: Impregnation temperature: 700~750℃ Immersion time: 10 to 15 minutes.

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