Preparation method of composite brake disc reinforced with carbon fiber woven mesh

Abstract

This invention provides a method for preparing a composite brake disc reinforced with a carbon fiber woven mesh, belonging to the field of brake disc manufacturing. By incorporating multiple layers of carbon fiber woven mesh into a ceramic matrix and employing a vacuum hot pressing process, this invention significantly improves the brake disc's thermal stability, wear resistance, and thermal cracking resistance. This brake disc is suitable for applications in high-performance automobiles and high-speed trains.

Description

Technical Field

[0001] The present invention relates to the field of brake disc preparation, in particular to a method for preparing a composite brake disc reinforced with a carbon fiber woven mesh. Background Art

[0002] As modern transportation evolves towards higher speeds, lighter weight, and greater safety, the performance requirements for braking systems are increasing. As a key component of the braking system, the material properties of brake discs directly impact the braking efficiency and safety of the vehicle. Traditional brake discs are mostly made of cast iron. While this offers excellent machinability and cost advantages, it suffers from issues such as heavy weight, low thermal conductivity, and susceptibility to thermal decay and cracking, making it difficult to meet the demands of high-performance vehicles.

[0003] To overcome these shortcomings, researchers have developed a variety of new brake disc materials. Among them, carbon / carbon (C / C) composites have become the material of choice in the aerospace industry due to their excellent high-temperature performance and low density. However, C / C composites exhibit low friction coefficients and poor oxidation resistance in wet environments, limiting their application in civilian vehicles.

[0004] To further enhance material performance, carbon / silicon carbide (C / SiC) composites have emerged. Based on C / C composites, these materials incorporate a silicon carbide (SiC) phase, significantly improving oxidation resistance and friction performance. C / SiC composites offer high specific strength, high specific modulus, excellent high-temperature mechanical properties, and thermal stability, and have found application in high-end automobiles and high-speed trains.

[0005] Despite the excellent performance of C / SiC composites, their complex preparation process and high cost have limited their large-scale application. Furthermore, traditional C / SiC composites often use chopped carbon fibers as reinforcement, which results in limited mechanical and impact resistance.

[0006] To address these issues, researchers have attempted to incorporate three-dimensional carbon fiber meshes as reinforcements to improve the overall performance of composite materials. Three-dimensional woven structures can provide reinforcement in multiple directions, significantly enhancing the material's mechanical properties and resistance to thermal cracking. However, effectively combining the three-dimensional carbon fiber mesh with a ceramic matrix to create a high-performance composite material remains a technical challenge.

[0007] Therefore, developing a method for preparing a composite brake disc reinforced with a carbon fiber woven mesh can not only give full play to the reinforcing effect of carbon fiber, but also simplify the preparation process and reduce costs. It has important practical significance and broad application prospects. Summary of the Invention

[0008] In view of the problems involved in the above-mentioned background technology, the present invention provides a method for preparing a composite brake disc reinforced with a carbon fiber woven mesh. By introducing multiple layers of carbon fiber woven mesh into a ceramic matrix and adopting a vacuum hot pressing molding process, the thermal stability, wear resistance and thermal crack resistance of the brake disc are significantly improved.

[0009] A method for preparing a composite brake disc reinforced with a carbon fiber woven mesh comprises the following steps:

[0010] a) Preparation of Carbon Fiber Braided Mesh: High-strength carbon fibers are selected and three-dimensional braiding technology is used to form a woven mesh with a thickness of 2-5 mm. High-strength carbon fibers provide excellent mechanical properties for the brake disc, and the three-dimensional braiding technology ensures good structural stability and uniformity of the mesh.

[0011] b) preparing a ceramic matrix material mixture, wherein the mixture comprises the following components in parts by mass:

[0012] Silicon carbide (SiC) powder: 60-80 parts; aluminum oxide (Al2O3) powder: 10-20 parts; silicon oxide (SiO2) powder: 5-10 parts; binder: 5-10 parts. Silicon carbide powder, with its high hardness, high temperature resistance, and wear resistance, serves as the primary reinforcement phase in the ceramic matrix. Aluminum oxide powder improves the matrix's strength and high temperature resistance; silicon oxide powder helps improve the matrix's sintering properties and chemical stability. The binder bonds the individual powder particles together and binds them to the carbon fiber mesh.

[0013] c) Alternately laying the carbon fiber mesh and the ceramic matrix material mixture to form a preform. This alternating laying method allows the carbon fiber mesh to be evenly distributed in the ceramic matrix, fully exerting its reinforcing effect.

[0014] d) Place the preform in a vacuum hot press furnace for hot pressing for 1-2 hours. The vacuum environment prevents oxidation of the material at high temperatures, and hot pressing allows the ceramic matrix material to be fully sintered and tightly bonded to the carbon fiber mesh.

[0015] e) After cooling, perform high-temperature annealing for 1-2 hours. High-temperature annealing can eliminate the internal stress generated during the molding process, improve the material structure, and enhance the performance stability of the brake disc.

[0016] f) Machining and surface polishing of the formed brake disc to meet the design size and surface quality requirements.

[0017] In one embodiment, the ceramic matrix material mixture includes silicon carbide powder with a particle size of 0.5-1 μm, aluminum oxide powder with a particle size of 0.5-1 μm, and silicon oxide powder with a particle size of 0.5-1 μm. Suitable powder particle sizes help improve the uniformity and sintering properties of the mixture, making the ceramic matrix more dense.

[0018] In one embodiment, the adhesive is selected from a high-temperature resistant organic metal adhesive, which can maintain good bonding performance in a high-temperature environment and ensure the bonding strength between the carbon fiber woven mesh and the ceramic matrix.

[0019] In one embodiment, the high temperature resistant organic metal binder is composed of the following components in parts by mass:

[0020] Titanium glycolate complex (CAS: 67729-57-1): 0.3-3 parts; 8-hydroxyquinoline nickel (CAS: 14100-15-3): 0.2-2.5 parts; carboxyl polyethylene glycol succinimide (CAS: 2414299-79-7, molecular weight 1000-2000): 100-200 parts; triethylamine: 5-10 parts; N,N-dimethylformamide (DMF): 1000-1500 parts. Titanium glycolate complex and 8-hydroxyquinoline nickel, as organometallic compounds, react chemically with the ceramic matrix and carbon fiber surfaces, enhancing bonding. Carboxyl polyethylene glycol succinimide exhibits excellent flexibility and compatibility, improving the adhesive's processing properties and bonding strength with other materials. Triethylamine acts as a catalyst to promote the reaction, and DMF acts as a solvent to dissolve the components and form a uniform solution.

[0021] In one embodiment, the preparation method of the high-temperature resistant organic metal binder includes the following steps: dissolving a titanium hydroxyacetate complex and carboxyl polyethylene glycol succinimide in DMF, stirring at 66-75°C for 3-5 hours to form a metal organic prepolymer, during which the titanium hydroxyacetate complex and carboxyl polyethylene glycol succinimide undergo a preliminary reaction to form a prepolymer with a certain structure.

[0022] Add 8-hydroxyquinoline nickel and triethylamine, and heat to 80-90°C for 3-6 hours. Further reaction forms more complex chemical bonds between the components, improving the performance of the adhesive.

[0023] The DMF is partially removed by vacuum distillation, and the solid content is adjusted to 40-50% to obtain a high-temperature resistant organometallic binder. Adjusting the solid content ensures the binder has the appropriate viscosity for use in the composite brake disc manufacturing process.

[0024] In one embodiment, the hot pressing molding temperature is 1600-1800°C and the pressure is 10-20 MPa.

[0025] In one embodiment, the high temperature annealing temperature is 1400-1600°C.

[0026] Beneficial Effects: By using a carbon fiber mesh to reinforce a ceramic matrix, combined with a specific high-temperature-resistant organic metal binder and a rational manufacturing process, the present invention produces a composite brake disc with high strength, high-temperature resistance, and excellent wear resistance, meeting the high-performance demands of modern vehicles. Furthermore, the high-temperature-resistant organic metal binder effectively strengthens the bond between the carbon fiber and the ceramic matrix, improving the overall performance of the composite brake disc. DETAILED DESCRIPTION

[0027] To make the purpose, technical solutions and advantages of the examples of the present application clearer, the technical solutions in the examples of the present application will be described clearly and completely below. Where specific conditions are not specified in the examples, conventional conditions or conditions recommended by the manufacturer are used. Where the manufacturer of the reagents or instruments is not specified, they are all conventional products that can be purchased commercially.

[0028] Example 1: A method for preparing a composite brake disc reinforced with a carbon fiber woven mesh, comprising the following steps:

[0029] 1) Preparation of carbon fiber woven mesh:

[0030] High-strength carbon fiber is selected and three-dimensional weaving technology is adopted to form a woven mesh with a thickness of 3 mm.

[0031] 2) Preparation of ceramic matrix material mixture:

[0032] Silicon carbide (SiC) powder: 70 kg (particle size 0.8 μm);

[0033] Alumina (AL2O3) powder: 15 kg (particle size 0.8 μm);

[0034] Silicon oxide (SiO2) powder: 7 kg (particle size 0.8 μm);

[0035] Adhesive: 5kg.

[0036] 3) Preparation of high temperature resistant organic metal binder:

[0037] 1.5 kg of titanium glycolate complex and 150 kg of carboxyl polyethylene glycol succinimide (molecular weight 1500) were dissolved in 1200 kg of DMF and stirred at 70°C for 4 hours to form a metal organic prepolymer.

[0038] 1.5 kg of 8-hydroxyquinoline nickel and 8 kg of triethylamine were added, the temperature was raised to 85 ° C and the reaction was carried out for 4 hours. Part of DMF was removed by distillation under reduced pressure, and the solid content was adjusted to 45% to obtain a high-temperature resistant organic metal binder.

[0039] 4) Alternate laying to form a prefabricated body:

[0040] The carbon fiber woven mesh and the ceramic matrix material mixture are laid alternately to form a preform.

[0041] 5) Hot pressing:

[0042] The preform was placed in a vacuum hot press furnace and kept at 1700°C and 15 MPa for 1.5 h.

[0043] 6) High temperature annealing treatment:

[0044] After cooling, high temperature annealing treatment was performed at 1500°C for 1.5 hours.

[0045] 7) Machining and surface polishing:

[0046] The molded brake disc is machined and surface polished to meet the design size and surface quality requirements.

[0047] Example 2: A method for preparing a composite brake disc reinforced with a carbon fiber woven mesh, comprising the following steps:

[0048] 1) Preparation of carbon fiber woven mesh:

[0049] High-strength carbon fiber is selected and three-dimensional weaving technology is adopted to form a woven mesh with a thickness of 2 mm.

[0050] 2) Preparation of ceramic matrix material mixture:

[0051] Silicon carbide (SiC) powder: 60 kg (particle size 0.5 μm);

[0052] Alumina (AL2O3) powder: 20 kg (particle size 0.5 μm);

[0053] Silicon oxide (SiO2) powder: 10 kg (particle size 0.5 μm);

[0054] Adhesive: 6.5kg.

[0055] 3) Preparation of high temperature resistant organic metal binder:

[0056] 0.3 kg of titanium glycolate complex and 100 kg of carboxyl polyethylene glycol succinimide (molecular weight 1000) were dissolved in 1000 kg of DMF and stirred at 66° C. for 5 hours to form a metal organic prepolymer.

[0057] 0.2 kg of 8-hydroxyquinoline nickel and 5 kg of triethylamine were added, the temperature was raised to 80 ° C and the reaction was carried out for 6 hours. Part of DMF was removed by distillation under reduced pressure, and the solid content was adjusted to 40% to obtain a high-temperature resistant organic metal binder.

[0058] 4) Alternate laying to form a prefabricated body:

[0059] The carbon fiber woven mesh and the ceramic matrix material mixture are laid alternately to form a preform.

[0060] 5) Hot pressing:

[0061] The preform was placed in a vacuum hot press furnace and kept at 1600 °C and 10 MPa for 2 h.

[0062] 6) High temperature annealing treatment:

[0063] After cooling, high temperature annealing treatment was performed at 1400°C for 2 hours.

[0064] 7) Machining and surface polishing:

[0065] The molded brake disc is machined and surface polished to meet the design size and surface quality requirements.

[0066] Example 3: A method for preparing a composite brake disc reinforced with a carbon fiber woven mesh, comprising the following steps:

[0067] 1) Preparation of carbon fiber woven mesh:

[0068] High-strength carbon fiber is selected and three-dimensional weaving technology is adopted to form a woven mesh with a thickness of 5 mm.

[0069] 2) Preparation of ceramic matrix material mixture:

[0070] Silicon carbide (SiC) powder: 80 kg (particle size 1 μm);

[0071] Alumina (AL2O3) powder: 10 kg (particle size 1 μm);

[0072] Silicon oxide (SiO2) powder: 5 kg (particle size 1 μm);

[0073] Adhesive: 8kg.

[0074] 3) Preparation of high temperature resistant organic metal binder:

[0075] 3 kg of titanium glycolate complex and 200 kg of carboxyl polyethylene glycol succinimide (molecular weight 2000) were dissolved in 1500 kg of DMF and stirred at 75°C for 3 hours to form a metal organic prepolymer.

[0076] 2.5 kg of 8-hydroxyquinoline nickel and 10 kg of triethylamine were added, the temperature was raised to 90 ° C and the reaction was carried out for 3 hours. Part of DMF was removed by distillation under reduced pressure, and the solid content was adjusted to 50% to obtain a high-temperature resistant organic metal binder.

[0077] 4) Alternate laying to form a prefabricated body:

[0078] The carbon fiber woven mesh and the ceramic matrix material mixture are laid alternately to form a preform.

[0079] 5) Hot pressing:

[0080] The preform was placed in a vacuum hot press furnace and kept at 1800 °C and 20 MPa for 1 h.

[0081] 6) High temperature annealing treatment:

[0082] After cooling, high temperature annealing treatment was performed at 1600°C for 1 hour.

[0083] 7) Machining and surface polishing:

[0084] The molded brake disc is machined and surface polished to meet the design size and surface quality requirements.

[0085] Example 4: A method for preparing a composite brake disc reinforced with a carbon fiber woven mesh, comprising the following steps:

[0086] 1) Preparation of carbon fiber woven mesh:

[0087] High-strength carbon fiber is selected and three-dimensional weaving technology is adopted to form a woven mesh with a thickness of 4 mm.

[0088] 2. Preparation of ceramic matrix material mixture:

[0089] Silicon carbide (SiC) powder: 75 kg (particle size 0.7 μm);

[0090] Alumina (AL2O3) powder: 12 kg (particle size 0.7 μm);

[0091] Silicon oxide (SiO2) powder: 8 kg (particle size 0.7 μm);

[0092] Adhesive: 10kg.

[0093] 3) Preparation of high temperature resistant organic metal binder:

[0094] 2 kg of titanium glycolate complex and 180 kg of carboxyl polyethylene glycol succinimide (molecular weight 1800) were dissolved in 1300 kg of DMF and stirred at 72° C. for 3.5 hours to form a metal organic prepolymer.

[0095] 2 kg of 8-hydroxyquinoline nickel and 7 kg of triethylamine were added, the temperature was raised to 88 ° C and the reaction was carried out for 4.5 hours. Part of DMF was removed by distillation under reduced pressure, and the solid content was adjusted to 48% to obtain a high-temperature resistant organometallic binder.

[0096] 4) Alternate laying to form a prefabricated body:

[0097] The carbon fiber woven mesh and the ceramic matrix material mixture are laid alternately to form a preform.

[0098] 5) Hot pressing:

[0099] The preform was placed in a vacuum hot press furnace and kept at 1750°C and 18 MPa for 1.2 h.

[0100] 6) High temperature annealing treatment:

[0101] After cooling, high temperature annealing treatment was performed at 1550°C for 1.2 hours.

[0102] 7) Machining and surface polishing:

[0103] The molded brake disc is machined and surface polished to meet the design size and surface quality requirements.

[0104] Comparative Example 1: A method for preparing a composite brake disc reinforced with a carbon fiber woven mesh, comprising the following steps:

[0105] 1) Preparation of carbon fiber woven mesh:

[0106] High-strength carbon fiber is selected and three-dimensional weaving technology is adopted to form a woven mesh with a thickness of 3 mm.

[0107] 2) Preparation of ceramic matrix material mixture:

[0108] Silicon carbide (SiC) powder: 70 kg (particle size 0.8 μm);

[0109] Alumina (AL2O3) powder: 15 kg (particle size 0.8 μm);

[0110] Silicon oxide (SiO2) powder: 7 kg (particle size 0.8 μm);

[0111] Adhesive: 8kg.

[0112] 3) Preparation of high temperature resistant organic metal binder:

[0113] 150 kg of carboxyl polyethylene glycol succinimide (molecular weight 1500) was dissolved in 1200 kg of DMF and stirred at 70°C for 4 hours to form a metal organic prepolymer.

[0114] 1.5 kg of 8-hydroxyquinoline nickel and 8 kg of triethylamine were added, the temperature was raised to 85 ° C and the reaction was carried out for 4 hours. Part of DMF was removed by distillation under reduced pressure, and the solid content was adjusted to 45% to obtain a high-temperature resistant organic metal binder.

[0115] 4) Alternate laying to form a prefabricated body:

[0116] The carbon fiber woven mesh and the ceramic matrix material mixture are laid alternately to form a preform.

[0117] 5) Hot pressing:

[0118] The preform was placed in a vacuum hot press furnace and kept at 1700°C and 15 MPa for 1.5 h.

[0119] 6) High temperature annealing treatment:

[0120] After cooling, high temperature annealing treatment was performed at 1500°C for 1.5 hours.

[0121] 7) Machining and surface polishing:

[0122] The molded brake disc is machined and surface polished to meet the design size and surface quality requirements.

[0123] Comparative Example 2: A method for preparing a composite brake disc reinforced with a carbon fiber woven mesh, comprising the following steps:

[0124] 1) Preparation of carbon fiber woven mesh:

[0125] High-strength carbon fiber is selected and three-dimensional weaving technology is adopted to form a woven mesh with a thickness of 3 mm.

[0126] 2) Preparation of ceramic matrix material mixture:

[0127] Silicon carbide (SiC) powder: 70 kg (particle size 0.8 μm);

[0128] Alumina (AL2O3) powder: 15 kg (particle size 0.8 μm);

[0129] Silicon oxide (SiO2) powder: 7 kg (particle size 0.8 μm);

[0130] Adhesive: 8kg.

[0131] 3) Preparation of high temperature resistant organic metal binder:

[0132] 1.5 kg of titanium glycolate complex and 150 kg of carboxyl polyethylene glycol succinimide (molecular weight 1500) were dissolved in 1200 kg of DMF and stirred at 70°C for 4 hours to form a metal organic prepolymer.

[0133] 8 kg of triethylamine was added, the temperature was raised to 85 ° C, and the reaction was carried out for 4 hours. Part of DMF was removed by distillation under reduced pressure, and the solid content was adjusted to 45% to obtain a high-temperature resistant organometallic binder.

[0134] 4) Alternate laying to form a prefabricated body:

[0135] The carbon fiber woven mesh and the ceramic matrix material mixture are laid alternately to form a preform.

[0136] 5) Hot pressing:

[0137] The preform was placed in a vacuum hot press furnace and kept at 1700°C and 15 MPa for 1.5 h.

[0138] 6) High temperature annealing treatment:

[0139] After cooling, high temperature annealing treatment was performed at 1500°C for 1.5 hours.

[0140] 7) Machining and surface polishing:

[0141] The molded brake disc is machined and surface polished to meet the design size and surface quality requirements.

[0142] Test method:

[0143] 1. Mechanical properties test

[0144] Test items: flexural strength, compressive strength, impact toughness.

[0145] Test standard: Based on the national standard GB / T 1449-2005 "Fiber reinforced plastics bending performance test method".

[0146] Testing equipment: universal material testing machine, loading rate is 2 mm / min.

[0147] Sample preparation: Specimens with dimensions of 80 mm × 10 mm × 4 mm were cut from the prepared brake discs and subjected to three-point bending tests.

[0148] The test results of the embodiments and comparative examples obtained by the above test methods are shown in Table 1 below:

[0149] Table 1: Mechanical properties test results of various embodiments and comparative examples

[0150]

[0151] 2. Thermal stability test

[0152] Test items: thermal conductivity, thermal expansion coefficient.

[0153] Test standard: Based on the national standard GB / T 2570-2000 "Determination of thermal conductivity".

[0154] Testing equipment: Thermomechanical Analyzer (TMA), Laser Flash Thermal Conductivity Meter.

[0155] Test conditions: Temperature range is room temperature to 1000°C, and the heating rate is 5°C / min.

[0156] The test results of the embodiments and comparative examples obtained by the above test methods are shown in Table 2 below:

[0157] Table 2: Thermal stability test results of various embodiments and comparative examples

[0158]

[0159] 3. Friction performance test

[0160] Test items: friction coefficient, wear rate.

[0161] Test standard: Based on the national standard GB / T 5763-2008 "Automotive Brake Linings".

[0162] Test equipment: small inertia bench test machine.

[0163] Test conditions: initial temperature of 100°C, maximum temperature of 600°C, loading pressure of 1 MPa, and sliding speed of 10 m / s.

[0164] The test results of the embodiments and comparative examples obtained by the above test methods are shown in Table 3 below:

[0165] Table 3: Friction performance test results of various embodiments and comparative examples

[0166]

[0167] In summary, through standardized testing methods and comparative experimental results, the significant advantages of the present invention in mechanical properties, thermal stability and friction performance are fully verified, and it meets the application requirements of high-performance brake discs.

[0168] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A method for preparing a composite brake disc reinforced with a carbon fiber woven mesh, characterized in that: The following steps are involved: a) Preparation of carbon fiber woven mesh: Select high-strength carbon fiber and use three-dimensional weaving technology to form a woven mesh with a thickness of 2-5 mm; b) preparing a ceramic matrix material mixture, wherein the mixture comprises the following components in parts by mass: Silicon carbide powder: 60-80 parts; Alumina powder: 10-20 parts; Silicon oxide powder: 5-10 parts; Binder: 5-10 parts; c) alternately laying a mixture of carbon fiber woven mesh and ceramic matrix material to form a preform; d) placing the preform in a vacuum hot pressing furnace for hot pressing and holding the preform for 1-2 hours; e) After cooling, perform high temperature annealing for 1-2 hours; f) Machining and surface polishing the molded brake disc to meet the design size and surface quality requirements; The binder is a high-temperature resistant organic metal binder, which is prepared by reacting 0.3-3 parts of titanium hydroxyacetate complex, 0.2-2.5 parts of 8-hydroxyquinoline nickel, 100-200 parts of carboxyl polyethylene glycol succinimide with a molecular weight of 1000-2000, 5-10 parts of triethylamine, and 1000-1500 parts of N,N-dimethylformamide; The preparation method of the high temperature resistant organic metal binder comprises the following steps: The titanium hydroxyacetate complex and carboxyl polyethylene glycol succinimide are dissolved in DMF and stirred at 66-75°C for 3-5 hours to form a metal organic prepolymer. 8-Hydroxyquinoline nickel and triethylamine are added, and the temperature is raised to 80-90°C for reaction for 3-6 hours. Part of the DMF is removed by vacuum distillation, and the solid content is adjusted to 40-50% to obtain a high-temperature resistant organic metal binder.

2. The method for preparing a composite brake disc reinforced with a carbon fiber woven mesh according to claim 1, characterized in that: In the ceramic matrix material mixture, the particle size of the silicon carbide powder is 0.5-1 μm, the particle size of the aluminum oxide powder is 0.5-1 μm, and the particle size of the silicon oxide powder is 0.5-1 μm.

3. The method for preparing a composite brake disc reinforced with a carbon fiber woven mesh according to claim 1, characterized in that: The hot pressing molding temperature is 1600-1800° C. and the pressure is 10-20 MPa.

4. The method for preparing a carbon fiber braided mesh reinforced composite brake disc according to claim 1, characterized in that: The high temperature annealing temperature is 1400-1600°C.

Images