Method for manufacturing a brake disc or brake drum, brake disc or brake drum, use of aluminum alloy for manufacturing a brake disc or brake drum, and disc brake or drum brake

Abstract

This document describes a method for manufacturing a brake disc or brake drum, particularly an automotive brake disc or brake drum, which is made of at least part aluminum alloy. Aluminum alloys consist of the following alloying elements, measured by weight percentage: silicon: 8.5% to 19.5%, nickel: 0.7% to 3.2%, copper: 0.7% to 5.2%, magnesium: 0.5% to 1.5%, manganese: up to 0.5%, iron: up to 0.8%, zirconium: up to 0.4%, vanadium: up to 0.3%, titanium: up to 0.2%, phosphorus: up to 0.015%, zinc: up to 0.5%, lead: up to 0.08%, tin: up to 0.1%, antimony: up to 0.015%, chromium: up to 0.05%, calcium: up to 0.002%, sodium: up to 0.02%, strontium: up to 0.02%, lithium: up to 0.0015%, boron: up to 0.0005%, and beryllium: up to 0.0005%, with the remainder being aluminum and unavoidable impurities. The present invention also describes brake discs or brake drums for automobiles, in particular brake discs or brake drums for automobiles, in which at least a portion is composed of the aforementioned alloys, and the use of alloys for manufacturing brake discs or brake drums.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a brake disc or a brake drum from an aluminum alloy, a brake disc or a brake drum at least partially manufactured from an aluminum alloy, the use of an aluminum alloy for manufacturing a brake disc or a brake drum, and a disc brake or a drum brake.

Background Art

[0002] In recent years, there has been an increasing demand for economical and even more ecological means of transport, which need to meet high requirements regarding consumption and emissions. In the field of motor vehicles, under such circumstances, more and more attention is being paid to components that have not been given much attention before. In particular, brake discs and brake drums of mechanical brake systems have the potential for development for significant technical improvements.

[0003] Furthermore, the use of these conventional brake discs in particular results in the emission of a large amount of fine particles in the form of brake dust due to the wear of the frictionally contacting brake discs and brake pads. Considering health aspects, legislators have determined threshold values for these fine particle emissions. For this reason too, alternative materials for brake discs with low fine particle emissions are needed.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Finally, as the use of battery electric vehicles or hybrid electric vehicles (BEVs / HEVs) increases, brake discs or brake drums with improved corrosion resistance will be required. This is due to the fact that the aforementioned vehicles operate primarily using regenerative systems for braking energy. When these systems are in use, braking of the vehicle is mainly done via regenerative braking, and the mechanical brake system intervenes only when the vehicle needs to be braked suddenly or kept at a stop. In vehicles without regenerative braking, the normal use of mechanical brakes prevents substantial surface oxidation of the brake discs because each braking process causes wear on the brake disc surface. However, in BEV / HEV vehicles with regenerative braking, the use of mechanical brakes is very rare, and eventually, a considerable layer of oxidation can form on the brake discs. This poses a safety risk, especially when a large deceleration (i.e., sudden braking) of the vehicle is required after a long period of non-use of the mechanical brakes, as the oxidation layer on the brake discs reduces the necessary friction between the brake disc and the brake pads. However, the brake system must always be used to provide optimal braking effect in the event of emergency braking. [Means for solving the problem]

[0005] Because brake drum systems are closed systems, they are preferable to brake disc systems in terms of potential particulate matter emission. However, the other technical requirements and potential improvements mentioned above also apply to brake drums. Therefore, in the context of the present invention, brake drums having the specifications and advantages described below are also described and claimed.

[0006] In summary, alternative materials for brake discs and brake drums are needed that take into account the aforementioned new challenges.

[0007] Against this backdrop, International Publication No. WO8903895A1 describes a brake disc made of aluminum alloy. The aluminum alloy consists of 14% to 16% silicon, 1.9% to 2.2% copper, 1.0% to 1.4% nickel, 0.4% to 0.55% magnesium, 0.6% to 1.0% iron, 0.3% to 0.6% manganese, and 0.02% to 0.1% silicon modifier, with the remainder being aluminum and unavoidable impurities. Strontium is described as an example of a silicon modifier.

[0008] International Publication WO2019 / 063034 A1 discloses a disc brake made of a hypereutectic aluminum / silicon alloy, which may contain 13 to 21 wt% silicon, 0.2 to 0.7 wt% magnesium, up to 0.001 wt% strontium, up to 0.2 wt% iron, 0.06 to 0.1 wt% titanium, up to 0.3 wt% copper, and aluminum as the remainder.

[0009] Chinese Patent No. CN113930645A describes an automobile brake disc comprising a brake disc body and a wear-resistant layer embedded in the brake surface of the brake disc body. In this case, the brake disc body is manufactured from an aluminum alloy material consisting of 70 to 92% aluminum, 0.1 to 8% silicon, 0.1 to 2.6% copper, 0.1 to 3.0% magnesium, 0.1 to 6% zinc, 0.1 to 0.5% manganese, 0.1 to 0.5% chromium, 0 to 0.5% nickel, 0.1 to 0.5% erbium, and 0.1 to 0.5% zirconium.

[0010] Chinese No. CN103115098B describes a brake disc composed of silicon: 17 to 35%, copper: 1 to 3%, magnesium: 0.3 to 2%, nickel or chromium: 1 to 2%, and aluminum as the remainder.

[0011] U.S. Patent No. 6,168,675 describes an aluminum alloy composition comprising about 12 to 22 mass% silicon, about 2.5 to 4.5 mass% nickel, about 0.2 to 0.6 mass% magnesium, up to about 1.2 mass% manganese, up to about 1.2 mass% iron, and about 0.005 to 0.015 mass% phosphorus. This alloy composition may further contain up to about 0.25 wt% vanadium, up to about 0.2 wt% zirconium, up to about 0.25 wt% titanium, and up to about 2 wt% cerium and / or mischmetal. This alloy is proposed for the manufacture of various cast automotive parts, including disc brake frames for vehicles.

[0012] German Patent No. DE102011121292A1 relates to a brake disc made of an aluminum matrix composite alloy containing at least 40 volume% silicon carbide particles in the matrix forming aluminum alloy. The base aluminum matrix composite alloy used in the manufacture has a composition of 12 to 20 volume% Si, 3.0 to 8.0 volume% Fe, 2.0 to 5.0 volume% Ni, 0.5 to 3.0 volume% Mn, 0.5 to 2.0 volume% Mg, 0.3 to 2.0 volume% Cr, 12.0 to 25.0 volume% SiC particles, and aluminum with trace amounts of impurities making up the remaining 100 volume%.

[0013] European Patent No. EP3342890B1 discloses an aluminum casting alloy comprising 11.5 to 12 wt% silicon, 0.3 to 1 wt% iron, 0.05 to 0.4 wt% copper, less than 0.75 wt% manganese, less than 0.35 wt% zinc, 0.45 to 0.8 wt% magnesium, less than 0.3 wt% titanium, 0.05 to 0.2 wt% chromium, less than 0.3 wt% nickel, less than 0.05 wt% strontium, less than 0.05 wt% lead, less than 0.05 wt% tin, and the remainder being aluminum.

[0014] European Patent No. 2865774A1 describes an aluminum casting alloy comprising 7 to 11 mass% silicon, 0.6 to 1 mass% iron, 4 to 5 mass% copper, 0.05 to 0.5 mass% manganese, 0.05 to 1.2 mass% zinc, 0.56 to 0.9 mass% magnesium, 0.01 to 0.15 mass% titanium, 0.01 to 0.1 mass% chromium, 0.01 to 0.1 mass% nickel, 0.01 to 0.1 mass% lead, and 0.01 to 0.1 mass% tin.

[0015] International Publication No. WO2014 / 076174A1 proposes an alloy for the manufacture of engine parts, an aluminum alloy comprising, as alloying elements, 9% to 10.5% silicon, more than 2.0% to less than 3.5% nickel, more than 3.7% to 5.2% copper, less than 1% cobalt, 0.5% to 1.5% magnesium, 0.1% to 0.7% iron, 0.1% to 0.4% manganese, more than 0.1% to less than 0.2% zirconium, more than 0.1% to less than 0.2% vanadium, 0.05% to less than 0.2% titanium, 0.004% to 0.008% phosphorus, and the remainder being aluminum and unavoidable impurities.

[0016] International Publication No. WO2015 / 173172A1 describes alloys for the manufacture of engine parts, and aluminum alloys include, as alloying elements, 7 to less than 14.5 wt% silicon, more than 1.2 wt% and less than 4 wt% nickel, more than 3.7 wt% and less than 10 wt% copper, less than 1 wt% cobalt, 0.1 to 1.5 wt% magnesium, 0.1 to 0.7 wt% iron, 0.1 to less than 0.7 wt% manganese, 0.1 wt% to less than 0.5 wt% zirconium, 0.1 wt% to 0.3 wt% vanadium, 0.05 to 0.5 wt% titanium, 0.004 wt% to 0.05 wt% phosphorus, and the remainder being aluminum and unavoidable impurities. Optionally, aluminum alloys may also contain beryllium and calcium.

[0017] Finally, European Patent No. 4130505B1 describes a brake drum having a special shape and manufactured from a hypereutectic Al-Si alloy. [Modes for carrying out the invention]

[0018] The object of the present invention is to provide a brake disc or brake drum having low dead load, enhanced corrosion resistance and enhanced wear resistance, as well as a method for manufacturing the same.

[0019] These objectives are achieved by the method for manufacturing a brake disc or brake drum according to claim 1, the brake disc or brake drum according to claim 7, the use of an aluminum alloy for manufacturing a brake disc or brake drum according to claim 13, and the disc system according to claim 14. Further preferred embodiments of the present invention will become apparent in this regard from the dependent claims.

[0020] The aluminum alloy used in this invention contains the following alloying elements, measured in weight percentages: Silicon: 8.5% to 19.5% Nickel: 0.7% to 3.2% Copper: 0.7% to 5.2% Magnesium: 0.5% to 1.5% Manganese: up to 0.5% Iron: up to 0.8% Zirconium: up to 0.4% Vanadium: up to 0.3% Titanium: up to 0.2% Phosphorus: Maximum 0.015% Zinc: up to 0.5% Lead: max. 0.08% Tin: Maximum 0.1% Antimony: up to 0.015% Chromium: up to 0.05% Calcium: up to 0.002% Sodium: Maximum 0.02% Strontium: up to 0.02% Lithium: maximum 0.0015% Boron: maximum 0.0005%, and Beryllium: maximum 0.0005%, and aluminum and unavoidable impurities as the balance.

[0021] The aluminum alloy used according to the present invention has the necessary and suitable upper and lower limits (mass percent) of alloy elements as defined in the claims. More suitable upper and lower limits are: Silicon (Si): preferably 17.0% or less, Nickel (Ni): preferably at least 1.0%. Preferably 2.8% or less, Copper (Cu): preferably 1.0% or more. Preferably 4.7% or less, Manganese (Mn): preferably at least 0.05%. Preferably 0.25% or less, Iron (Fe): preferably at least 0.3%, Zirconium (Zr): preferably 0.15% or more. Preferably 0.25% or less, Vanadium (V): preferably at least 0.10%. Preferably 0.20% or less, Titanium (Ti): preferably 0.05% or more. Preferably 0.15% or less.

[0022] The balance of the alloy consists of aluminum and unavoidable impurities. The above elements for which the lower limit of the concentration range is not described are optional. In a preferred embodiment, the impurities are limited to a total content of 0.15%. Particularly preferably, the individual impurity elements are limited to a content of less than 0.05%.

[0023] Surprisingly, the alloy according to the present invention has been found to have not only excellent high-temperature resistance but also extremely good wear resistance. Further, this alloy is highly corrosion-resistant, and due to the high proportion of low-density alloy elements, it is possible to manufacture particularly lightweight brake disks and brake drums.

[0024] In this case, the alloy composition described in the dependent claim has particularly significant material properties with respect to high temperature resistance and wear resistance. In this case, copper contributes to mechanical strength, particularly by forming primary and secondary phases. Strontium is an antagonist to phosphorus, and the strontium content should be kept as low as possible so as to ensure the formation of primary silicon particles. The above upper limit for iron prevents adverse effects on strength. Titanium is particularly present at 0.12%, in which case good grain refinement is possible, and thus contributes to mechanical strength.

[0025] Furthermore, in the manufacture of brake discs and brake drums, gravity die casting has been recognized as particularly suitable for meeting material quality requirements for cast products, especially brake disc blanks or brake drum blanks.

[0026] In another significant embodiment, after casting, silicon crystals deposited on the surface during the hardening process are exposed by chemical etching. This process step further enhances the wear resistance of the brake disc and brake drum.

[0027] More preferably, the brake disc or brake drum is made entirely of the aforementioned aluminum alloy.

[0028] In particular, brake discs or brake drums made entirely of aluminum alloy do not have a composite material structure, nor do they have a metal matrix composite material structure. Such types of brake discs or brake drums are easier to manufacture and can be recycled.

[0029] Preferably, the brake drum in particular is insert-free, meaning it does not contain any inserts or other structural members, such as those made of cast iron. Such inserts have adverse effects on corrosion and particle properties, as well as weight. Furthermore, avoiding inserts, especially those made of iron, can prevent adverse effects on contact between the brake drum and the pads. Even more preferably, the brake disc, and in particular the brake drum, is formed as a single piece.

[0030] In principle, brake discs or brake drums may further include additional coatings and / or layers of another material formed by process-related effects of the surface material (such as hard anodizing). However, it is preferable that brake discs or brake drums do not include any such additional layers or coatings. The excellent properties of the aluminum alloy used make it possible to omit coatings, thereby making the manufacturing process more efficient.

[0031] The present invention further includes brake systems, particularly for automobiles, especially disc brakes and drum brakes, which have the brake discs and brake drums described herein as system components and possess the technical features and advantages thereof.

Claims

1. A method for manufacturing a brake disc or brake drum, particularly a brake disc or brake drum for an automobile, which is made of at least a portion of an aluminum alloy, The aforementioned aluminum alloy contains the following alloying elements, measured in weight percentage: Silicon: 8.5% to 19.5% Nickel: 0.7% to 3.2% Copper: 0.7% to 5.2% Magnesium: 0.5% to 1.5% Manganese: up to 0.5% Iron: up to 0.8% Zirconium: up to 0.4% Vanadium: up to 0.3% Titanium: up to 0.2% Phosphorus: Maximum 0.015% Zinc: up to 0.5% Lead: 0.08% maximum Tin: Maximum 0.1% Antimony: up to 0.015% Chromium: up to 0.05% Calcium: up to 0.002% Sodium: up to 0.02% Strontium: up to 0.02% Lithium: Up to 0.0015% Boron: up to 0.0005%, and Beryllium: up to 0.0005%, and Aluminum and unavoidable impurities as the remainder A method consisting of the following elements.

2. The aforementioned aluminum alloy contains the following alloying elements, measured in weight percentage: Silicon: 8.5% to 11.5% Nickel: 1.7% to 3.2% Copper: 3.7% to 5.2% Magnesium: 0.5% to 1.5% Manganese: 0.1% to 0.4% Iron: up to 0.6% Zirconium: 0.1% to 0.4% Vanadium: 0.05% to 0.3% Titanium: up to 0.2% Phosphorus: Maximum 0.010% Zinc: up to 0.1% Lead: 0.08% maximum Tin: Maximum 0.08% Antimony: up to 0.015% Chromium: up to 0.03% Calcium: up to 0.0005% Sodium: Maximum 0.0005% Strontium: up to 0.0005% Lithium: Up to 0.0005% Boron: up to 0.0005%, and Beryllium: up to 0.0005%, and Aluminum and unavoidable impurities as the remainder The method according to claim 1, comprising:

3. The aforementioned aluminum alloy contains the following alloying elements, measured in weight percentage: Silicon: 11.0% to 13.5% Nickel: 0.7% to 1.3% Copper: 0.7% to 1.5% Magnesium: 0.8% to 1.5% Manganese: up to 0.5% Iron: up to 0.8% Titanium: up to 0.2% Phosphorus: 0.002% to 0.012% Zinc: up to 0.5% Lead: 0.08% maximum Tin: Maximum 0.1% Calcium: up to 0.002% Sodium: Maximum 0.0015% Strontium: up to 0.0015%, and Lithium: up to 0.0015%, and Aluminum and unavoidable impurities as the remainder The method according to claim 1, comprising:

4. The aforementioned aluminum alloy contains the following alloying elements, measured in weight percentage: Silicon: 16.5% to 19.5% Nickel: 0.8% to 1.3% Copper: 0.8% to 1.5% Magnesium: 0.8% to 1.5% Manganese: up to 0.2% Iron: up to 0.75% Titanium: up to 0.2% Phosphorus: Maximum 0.015% Zinc: up to 0.2% Lead: 0.08% maximum Tin: Maximum 0.1% Antimony: up to 0.015% Chromium: up to 0.05% Calcium: up to 0.001% Sodium: Maximum 0.001% Strontium: up to 0.001%, and Lithium: up to 0.0010%, and Aluminum and unavoidable impurities as the remainder The method according to claim 1, comprising:

5. The method according to any one of claims 1 to 4, wherein the aluminum alloy is injected by gravity die casting.

6. The method according to any one of claims 1 to 5, wherein the surface intended to interact with the brake disc or the brake drum, preferably the brake pad, is subjected to chemical etching after gravity die casting.

7. A brake disc or brake drum, particularly an automotive brake disc or brake drum, which is made of at least a portion of an aluminum alloy, The aforementioned aluminum alloy contains the following alloying elements, measured in weight percentage: Silicon: 8.5% to 19.5% Nickel: 0.7% to 3.2% Copper: 0.7% to 5.2% Magnesium: 0.5% to 1.5% Manganese: up to 0.5% Iron: up to 0.8% Zirconium: up to 0.4% Vanadium: up to 0.3% Titanium: up to 0.2% Phosphorus: Maximum 0.015% Zinc: up to 0.5% Lead: 0.08% maximum Tin: Maximum 0.1% Antimony: up to 0.015% Chromium: up to 0.050% Calcium: up to 0.002% Sodium: up to 0.02% Strontium: up to 0.02% Lithium: Up to 0.0015% Boron: up to 0.0005%, and Beryllium: up to 0.0005%, and Aluminum and unavoidable impurities as the remainder A brake disc or brake drum composed of these elements.

8. The aforementioned aluminum alloy contains the following alloying elements, measured in weight percentage: Silicon: 8.5% to 11.5% Nickel: 1.7% to 3.2% Copper: 3.7% to 5.2% Magnesium: 0.5% to 1.5% Manganese: 0.1% to 0.4% Iron: up to 0.6% Zirconium: 0.1% to 0.4% Vanadium: 0.05% to 0.3% Titanium: up to 0.2% Phosphorus: Maximum 0.010% Zinc: up to 0.1% Lead: 0.08% maximum Tin: Maximum 0.08% Antimony: up to 0.015% Chromium: up to 0.03% Calcium: up to 0.0005% Sodium: Maximum 0.0005% Strontium: up to 0.0005% Lithium: Up to 0.0005% Boron: up to 0.0005%, and Beryllium: up to 0.0005%, and Aluminum and unavoidable impurities as the remainder A brake disc or brake drum according to claim 7, comprising the above.

9. The aforementioned aluminum alloy contains the following alloying elements, measured in weight percentage: Silicon: 11.0% to 13.5% Nickel: 0.7% to 1.3% Copper: 0.7% to 1.5% Magnesium: 0.8% to 1.5% Manganese: up to 0.5% Iron: up to 0.8% Titanium: up to 0.2% Phosphorus: 0.002% to 0.012% Zinc: up to 0.5% Lead: 0.08% maximum Tin: Maximum 0.1% Calcium: up to 0.002% Sodium: Maximum 0.0015% Strontium: up to 0.0015%, and Lithium: up to 0.0015%, and Aluminum and unavoidable impurities as the remainder A brake disc or brake drum according to claim 7, comprising the above.

10. The aforementioned aluminum alloy contains the following alloying elements, measured in weight percentage: Silicon: Up to 16.5% to 19.5% Nickel: Up to 0.8% to 1.3% Copper: Up to 0.8% to 1.5% Magnesium: Up to 0.8% to 1.5% Manganese: up to 0.2% Iron: up to 0.75% Titanium: up to 0.2% Phosphorus: Maximum 0.015% Zinc: up to 0.2% Lead: 0.08% maximum Tin: Maximum 0.1% Antimony: up to 0.015% Chromium: up to 0.050% Calcium: up to 0.001% Sodium: Maximum 0.001% Strontium: up to 0.001%, and Lithium: up to 0.0010%, and Aluminum and unavoidable impurities as the remainder A brake disc or brake drum according to claim 7, comprising the above.

11. The brake disc or brake drum is entirely made of the aluminum alloy, and / or The brake disc or brake drum according to any one of claims 7 to 10, wherein the brake drum is insert-free.

12. The brake disc or brake drum according to any one of claims 7 to 11, wherein the brake disc or brake drum has no coating.

13. The use of aluminum alloy for manufacturing brake discs or brake drums, particularly for automotive brake discs or brake drums, The aluminum alloy is the alloy described in any one of claims 1 to 4.

14. A disc brake or drum brake comprising a brake disc or brake drum according to any one of claims 7 to 12.

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