A lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement

Abstract

The application discloses a kind of based on carbon steel core and multi-fiber three-dimensional composite reinforced lightweight axle materials, it is related to composite material technical field, a kind of based on carbon steel core and multi-fiber three-dimensional composite reinforced lightweight axle materials, including carbon steel core, multi-fiber composite material layer and outer surface metal coating, the carbon steel core is cylindrical, the multi-fiber composite material layer is set between carbon steel core and outer surface metal coating, the carbon steel core is provided with the support assembly for the auxiliary support of outer surface metal coating, the carbon steel core is made of carbon steel and alloy steel.The application innovatively designs a kind of based on carbon steel core and multi-fiber composite layer synergistic reinforced high-strength impact-resistant axle material, including metal matrix support layer, fiber orthogonal reinforcing layer, gradient transition layer and monitoring shell, break through the strength and toughness bottleneck of traditional material, significantly improve the load capacity and durability of axle structure, reduce the cost of composite material.

Description

Technical Field

[0001] This invention relates to the field of composite material technology, specifically to a lightweight axle material based on a carbon steel core and multi-fiber three-dimensional composite reinforcement. Background Technology

[0002] The axle, a crucial load-bearing and transmission component of a commercial vehicle chassis, accounts for approximately 15% of the chassis's weight. Lightweighting the axle can reduce energy consumption in commercial vehicles and promote the industry's green and low-carbon development. Lightweighting raw materials is the starting point for achieving lightweighting. Currently, lightweight materials for automotive parts mainly focus on high-strength steel, lightweight aluminum-magnesium alloys, and composite materials. High-strength steel is the most important lightweight material in the automotive industry, while the application of lightweight aluminum-magnesium alloys is gradually increasing. However, the weight reduction of high-strength steel is not significant, and aluminum-magnesium alloys are costly and have complex molding processes. Fiber composite materials have low density, good formability, corrosion resistance, shock absorption, sound insulation, and heat insulation properties, achieving a weight reduction of 40%-50% compared to steel components. In the global trend of green and lightweight automotive manufacturing, there is an urgent need to develop the application of high-strength, low-cost fiber composite materials in axles.

[0003] In recent years, although carbon fiber reinforced composite materials have been gradually applied to the automotive parts industry due to their high strength properties, significant technical defects have been exposed in practical engineering applications: 1. The raw material cost of pure carbon fiber composite materials is several times that of traditional steel; 2. Although carbon fiber bundles have excellent axial tensile strength, their bending modulus is insufficient and their outer layer impact toughness is low, making it difficult to meet the dynamic load-bearing requirements of vehicle axles. The systematic superposition of the aforementioned technical defects has become a key bottleneck restricting the lightweight and green development of commercial vehicle axles. To address this, we propose a lightweight axle material based on a carbon steel core and multi-fiber three-dimensional composite reinforcement. Summary of the Invention

[0004] The purpose of this invention is to provide a lightweight axle material based on a carbon steel core and multi-fiber three-dimensional composite reinforcement, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a lightweight axle material based on a carbon steel core and multi-fiber three-dimensional composite reinforcement, comprising a carbon steel core, a multi-fiber composite material layer, and an outer surface metal coating. The carbon steel core is cylindrical, and the multi-fiber composite material layer is disposed between the carbon steel core and the outer surface metal coating. The carbon steel core is provided with a support component for auxiliary support of the outer surface metal coating. The carbon steel core is made of carbon steel and alloy steel, and the diameter of the carbon steel core accounts for 5%-40% of the diameter of the axle material.

[0006] Preferably, the multi-fiber composite material layer includes multi-fiber material and polyester material. The multi-fiber material is based on a carbon steel core and is orthogonally wound on the carbon steel core. The polyester material is cast between the carbon steel core and the outer surface metal coating. The polyester material is made of epoxy resin, phenolic resin, and polyetheretherketone.

[0007] Preferably, the multi-fiber material is a fiber bundle composed of carbon fiber, glass fiber and polyester fiber, which is wound with large fiber bundles and has a diameter of 0.5-1mm, wherein the carbon fiber accounts for 10%-50%.

[0008] Preferably, the multi-fiber material is divided into transverse fibers and longitudinal fibers, and multiple sets of transverse fibers and longitudinal fibers are provided. The multiple sets of transverse fibers and longitudinal fibers are intertwined in a three-dimensional structure in which they are transversely and longitudinally interwoven in the multi-fiber composite material layer.

[0009] Preferably, the outer surface metal coating is applied to the outermost layer of the multi-fiber composite material layer, using a high-entropy alloy material and employing cold spraying technology, with a coating thickness of 100-1000μm.

[0010] Preferably, the carbon steel core has a first spiral groove on its surface.

[0011] Preferably, two sets of the support components are symmetrically arranged at the upper and lower ends of the carbon steel core.

[0012] Preferably, the support assembly consists of multiple radial support bars, and each group of radial support bars is installed and fixed to the end of the carbon steel core in a multi-directional distribution manner.

[0013] Preferably, the outer side of the radial support bar is provided with a second helical groove.

[0014] Preferably, the multi-fiber material adopts a multi-layer composite coating structure, forming a gradient reinforcement system by interweaving different types of fibers. The outermost layer of the multi-fiber material is composed of a carbon fiber layer, and the carbon fiber layer is covered with a flexible fiber layer.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention innovatively designs a high-strength impact-resistant axle material based on the synergistic reinforcement of a carbon steel core and a multi-fiber composite layer, including a metal matrix support layer, a fiber orthogonal reinforcement layer, a gradient transition layer, and a monitoring shell. It breaks through the strength and toughness bottlenecks of traditional materials, significantly improves the load-bearing capacity and durability of the axle structure, and reduces the cost of composite materials.

[0016] 2. The material adopts a three-dimensional reinforced composite structure. The carbon steel core provides high strength load-bearing capacity, the fiber orthogonal braided reinforcement layer improves tensile and bending performance, and the high-entropy alloy metal coating gives it impact resistance. The materials of each layer work together to achieve an optimized balance of high strength, lightweight and durability. 3. The surface of the carbon steel core column adopts a spiral groove design and electrochemical modification, which enables the fiber reinforcement layer to form a dual combination of mechanical interlocking and chemical bonding with the metal core, greatly improving the interfacial bonding strength and avoiding interlayer delamination failure; 4. The end face support structure optimizes bending resistance. Through the star-shaped end face support structure, multi-directional support is provided, so that the longitudinal fibers can obtain stable support when subjected to axial force, improve bending stiffness, and effectively resist deformation and fatigue failure during long-term service of the vehicle axle. 5. The fiber winding process adopts a circumferential and longitudinal interlacing weaving method. The transverse fibers enhance the circumferential constraint force and improve the tensile strength, while the longitudinal fibers enhance the axial load-bearing capacity and improve the bending stiffness, forming an efficient load-bearing network to ensure the stability of the material under multi-dimensional stress environment. 6. Adjustable design improves material adaptability. By adjusting the fiber weaving angle, composite material type, and cold spraying process parameters, the material properties can be gradient optimized according to the load requirements of different vehicles, thereby improving applicability. 7. Compared with traditional high-strength alloy steel axles, this material maintains high load-bearing capacity while reducing weight. By optimizing the material structure and fiber reinforcement method, the overall weight is reduced by more than 30%, effectively improving fuel economy and reducing energy consumption. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall external structure of the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the axle material of the present invention; Figure 3 This is a schematic diagram of the carbon steel core structure of the present invention; Figure 4 This is a top view schematic diagram of the lightweight axle material of the present invention; Figure 5 This is a schematic diagram of the internal structure of a single fiber bundle according to the present invention.

[0018] In the figure: 1. Carbon steel core; 101. Carbon fiber layer; 102. Flexible fiber layer; 2. Multi-fiber composite material layer; 201. Polyester material; 202. Transverse fiber; 203. Longitudinal fiber; 3. Outer surface metal coating; 4. First spiral groove; 5. Radial support bar; 6. Second spiral groove. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example

[0020] Please see Figures 1-5 The diagram shows a lightweight axle material based on a carbon steel core and multi-fiber three-dimensional composite reinforcement, comprising a carbon steel core 1, a multi-fiber composite material layer 2, and an outer surface metal coating 3. The carbon steel core 1 is cylindrical, and the multi-fiber composite material layer 2 is disposed between the carbon steel core 1 and the outer surface metal coating 3. The carbon steel core 1 is provided with support components for auxiliary support of the outer surface metal coating 3. The carbon steel core 1 is made of carbon steel and alloy steel, and the diameter of the carbon steel core 1 accounts for 5%-40% of the diameter of the axle material. It should be noted that: a first spiral groove 4 is formed on the surface of the carbon steel core 1, introducing micron-level structural grooves at the metal-fiber interface to enhance interfacial bonding and improve fiber interlocking stability. A star-shaped support structure is constructed on the end face of the carbon steel core 1, and an orthogonal three-dimensional woven multi-directional fiber network is used to surround the star-shaped support, optimizing the force transmission path and improving bending stiffness and tensile strength. The outer layer is prepared with a cold-working process to create a metal protective coating. High-entropy alloy metal materials enhance the material's impact resistance and reduce the impact of various environmental factors on the axle material, achieving a comprehensive enhancement of tensile strength, bending stiffness, and impact toughness. At the same time, it achieves significant weight reduction compared to traditional axle steel materials, improving fuel economy and service life. In addition, the material has high controllability; by adjusting the fiber weaving angle and adjusting the protective layer material parameters, performance gradient design and performance matching can be achieved to adapt to the needs of different application scenarios. This invention effectively solves key technical problems such as insufficient interfacial bonding capacity, poor impact resistance, and significant anisotropy of composite materials, providing an innovative solution for high-load-bearing lightweight axle structures.

[0021] Preferably, the multi-fiber composite material layer 2 includes multi-fiber material and polyester material 201. The multi-fiber material is based on carbon steel core 1 and is orthogonally three-dimensionally wound on carbon steel core 1. The polyester material 201 is cast between carbon steel core 1 and outer surface metal coating 3. The polyester material 201 is made of epoxy resin, phenolic resin and polyether ether ketone.

[0022] Preferably, the multi-fiber material is a fiber bundle composed of carbon fiber, glass fiber and polyester fiber, which is wound with large fiber bundles with a diameter of 0.5-1mm, of which carbon fiber accounts for 10%-50%; the multi-fiber material is divided into transverse fibers 202 and longitudinal fibers 203, and multiple sets of transverse fibers 202 and longitudinal fibers 203 are provided, and multiple sets of transverse fibers 202 and longitudinal fibers 203 are wound in the multi-fiber composite material layer 2 in a three-dimensional structure of transverse and longitudinal interweaving; It should be noted that the multi-fiber composite layer 2 is wound in a three-dimensional structure with interwoven transverse and longitudinal fibers. The multi-fiber composite layer 2 is manufactured using a continuous process similar to that of a spinning machine. The fiber bundles are uniformly wound under tension using a fiber spinning machine. After pretreatment, stretching, and resin impregnation, the fiber raw materials maintain fiber bundle integrity while ensuring good wettability and adhesion on the fiber surface. During the winding process, a step-by-step laying method is adopted, first laying transverse fibers 202, then laying longitudinal fibers 203, alternating layer by layer to form a high-strength composite structure. This ensures the uniformity of the fiber layers while improving the interfacial bonding quality. The fiber bundles are arranged sequentially at a certain angle, with the transverse fibers 202 circumferentially along the carbon steel core 1. The fiber winding provides strong circumferential restraint, preventing cracking or deformation of the structure under tension. The longitudinal fibers 203 are arranged in a straight line along the axial direction, providing high modulus support and improving the overall bending stiffness. At the fiber junctions, a stable bond is formed by mechanical interlocking, interfacial shear force, and resin curing, enabling the fiber layers to share the load and improving the overall structural stability. The fiber winding method combines helical laying and orthogonal weaving to ensure that the transverse fibers 202 form a ring-shaped support layer, while the longitudinal fibers 203 provide axial reinforcement, allowing the material to be subjected to balanced forces in multiple directions, improving tensile and bending resistance. The fiber layers are tightly bonded to the carbon steel core 1, filled in the helical grooves, and cured by interfacial impregnation and compaction, improving the bonding strength between the fibers and the metal and avoiding interlayer delamination failure.

[0023] Preferably, the outer surface metal coating 3 is applied to the outermost layer of the multi-fiber composite material layer 2, using a high-entropy alloy material and cold spraying technology, with a coating thickness of 100-1000μm.

[0024] Preferably, the surface of the carbon steel core 1 is provided with a first spiral groove 4; It should be noted that the carbon steel core 1 has a first spiral groove 4 on its surface, which is used to fill multi-fiber composite material to enhance the interfacial bonding force and improve the tensile and shear properties of the material. The carbon steel core 1 undergoes electrochemical modification treatment to further improve its interfacial bonding strength with the fiber layer and prevent interlayer delamination failure.

[0025] Preferably, two sets of support components are symmetrically arranged at the upper and lower ends of the carbon steel core 1; It should be noted here that two sets of support components are used to ensure more stable support.

[0026] Preferably, the support assembly consists of multiple radial support bars 5, and each set of radial support bars 5 is installed and fixed to the end of the carbon steel core 1 in a multi-directional distribution manner; It should be noted here that multiple sets of radial support bars 5 facilitate the installation and connection of multi-fiber materials.

[0027] Preferably, the outer side of the radial support bar 5 is provided with a second spiral groove 6; It should be noted that the radial support bar 5 has a second spiral groove 6, which makes the arrangement of carbon fibers at the end more stable, effectively supports the longitudinal fiber winding, avoids local stress concentration, and thus improves the overall bending resistance.

[0028] Preferably, the multi-fiber material adopts a multi-layer composite coating structure, which forms a gradient reinforcement system by interweaving different types of fibers. The outermost layer of the multi-fiber material is composed of a carbon fiber layer 101, and the carbon fiber layer 101 is wrapped with a flexible fiber layer 102. It should be noted that a gradient reinforcement system is formed by interweaving different types of fibers. The outermost layer is composed of a carbon fiber layer 101, which has high modulus, high strength and good fatigue resistance. It is mainly used to provide excellent tensile strength and rigid support, ensuring that the fiber bundle is not easy to break or deform under stress. The carbon fiber layer 101 is covered with a flexible fiber layer 102. These fiber layers can effectively distribute the load, improve the impact resistance of the overall structure, and enhance the interfacial bonding strength to prevent interlaminar delamination failure. The carbon fiber provides strength support, while other fibers provide toughness and energy absorption, realizing an optimized design that combines rigidity and flexibility, effectively avoiding brittle failure of a single material under impact load.

[0029] This solution describes a lightweight axle material based on a carbon steel core and multi-fiber three-dimensional composite reinforcement, comprising the following steps: The surface of the carbon steel core 1 is provided with a first spiral groove 4, which introduces a micron-level structure groove at the metal-fiber interface to enhance the interfacial bonding force and improve the fiber interlocking stability. A cross-shaped support structure is constructed on the end face of the carbon steel core 1. The cross-shaped support is surrounded by an orthogonal three-dimensional woven multi-directional fiber network to optimize the force transmission path and improve bending stiffness and tensile strength. The outer layer is prepared with a cold working process to prepare a metal protective coating. The impact resistance of the material is improved by using high-entropy alloy metal materials, reducing the impact of various environmental factors on the axle material and achieving a comprehensive enhancement of tensile strength, bending stiffness and impact toughness. At the same time, it achieves a significant weight reduction compared with traditional axle steel materials, improving fuel economy and service life. Furthermore, the material possesses high adjustability; by adjusting the fiber weaving angle and the parameters of the protective layer material, performance gradient design and performance matching can be achieved to adapt to the needs of different application scenarios. This invention effectively solves key technical problems such as insufficient interfacial bonding ability, poor impact resistance, and significant anisotropy of composite materials, providing an innovative solution for high-load-bearing lightweight vehicle axle structures.

[0030] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0031] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement, comprising a carbon steel core (1), a multi-fiber composite material layer (2) and an outer surface metal coating (3), wherein the carbon steel core (1) is cylindrical, the multi-fiber composite material layer (2) is disposed between the carbon steel core (1) and the outer surface metal coating (3), and a support component for auxiliary support of the outer surface metal coating (3) is provided on the carbon steel core (1), wherein the carbon steel core (1) is made of carbon steel and alloy steel, and the diameter of the carbon steel core (1) accounts for 5%-40% of the diameter of the axle material.

2. The lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 1, characterized in that: The multi-fiber composite material layer (2) includes multi-fiber material and polyester material (201). The multi-fiber material is based on carbon steel core (1) and is orthogonally wound on carbon steel core (1). The polyester material (201) is cast between carbon steel core (1) and outer surface metal coating (3). The polyester material (201) is made of epoxy resin, phenolic resin and polyether ether ketone.

3. The lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 2, characterized in that: The multi-fiber material is a fiber bundle composed of carbon fiber, glass fiber and polyester fiber, which is wound with large fiber bundles with a diameter of 0.5-1mm, of which carbon fiber accounts for 10%-50%.

4. The lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 3, characterized in that: The multi-fiber material is divided into transverse fibers (202) and longitudinal fibers (203). Multiple sets of transverse fibers (202) and longitudinal fibers (203) are provided, and multiple sets of transverse fibers (202) and longitudinal fibers (203) are intertwined in a three-dimensional structure in the multi-fiber composite material layer (2) in both transverse and longitudinal directions.

5. The lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 1, characterized in that: The outer surface metal coating (3) is applied to the outermost layer of the multi-fiber composite material layer (2), using high-entropy alloy material and cold spraying technology, with a coating thickness of 100-1000μm.

6. The lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 1, characterized in that: The carbon steel core (1) has a first spiral groove (4) on its surface.

7. The lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 1, characterized in that: The support components are symmetrically arranged in two sets at the upper and lower ends of the carbon steel core 1.

8. A lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 7, characterized in that: The support assembly consists of multiple radial support bars (5), and each set of radial support bars (5) is installed and fixed to the end of the carbon steel core (1) in a multi-directional distribution manner.

9. A lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 8, characterized in that: The radial support bar (5) has a second spiral groove (6) on its outer side.

10. A lightweight axle material based on carbon steel core and multi-fiber three-dimensional composite reinforcement according to claim 2, characterized in that: The multi-fiber material adopts a multi-layer composite coating structure, forming a gradient reinforcement system through the interweaving of different types of fibers. The outermost layer of the multi-fiber material is composed of a carbon fiber layer (101), and the carbon fiber layer (101) is covered with a flexible fiber layer (102).

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