Sinter lining and production method for high-speed trains

Abstract

The invention relates to sinter brake lining and production method for high-speed trains which is designed to meet difficult requirements including friction coefficients, wear resistance, thermal conductivity, strength and environmental durability under various operating conditions, formulates production process stages and production data to optimize the production of brake lining with two different structures of main raw materials (1) namely Cu-Copper (A) or Cu-10Sn-Bronze (B), auxiliary materials, lubricants, friction modifiers, abrasives and fillers.

Description

[0001] SINTER LINING AND PRODUCTION METHOD FOR HIGH-SPEED TRAINS

[0002] TECHNICAL FIELD

[0003] The invention relates to the production of sinter linings for high-speed trains by powder metallurgy method.

[0004] PRIOR ART

[0005] High-speed trains, commonly referred to as HST, are advanced railway systems designed for fast travel at significantly higher speeds compared to conventional trains. These trains include the latest technologies, materials and design principles to achieve outstanding performance characteristics.

[0006] Facilitated Aerodynamics: High-speed trains have streamlined, aerodynamic designs to minimize air resistance. The shape of the train is optimized to reduce drag and allow efficient movement at high speeds.

[0007] Electric Drive: Most HSTs use electric drive systems operated by aerial catenary wires or a third rail. These systems contribute to safety and energy efficiency by providing precise control of acceleration and deceleration.

[0008] Advanced Line and Infrastructure: Special high-speed rail lines are designed with smoother curves and gentle gradients to accommodate high-speed travel. The tracks are built with continuously welded rails that eliminate joints for a smoother ride.

[0009] Regenerative Braking: HSTs often include regenerative braking systems that convert kinetic energy into electrical energy during braking. This captured energy can be fed back into the electricity grid or used to provide power to the train. Active Suspension: Active suspension systems adjust the ride height and stiffness of the train in real time to ensure stability and passenger comfort, especially at high speeds.

[0010] High-speed trains serve many critical purposes in transportation:

[0011] Efficient Long Distance Travel: HSTs are primarily designed for long-distance travel between major urban centers. They offer a faster alternative to air or highway travel, reducing travel time and congestion.

[0012] Reduced Carbon Footprint: By offering an environmentally friendly mode of transportation, HSTs help reduce greenhouse gas emissions compared to conventional cars and airplanes. Regenerative braking system contributes to energy efficiency.

[0013] Enhanced Connectivity: High-speed rail networks efficiently connect cities and regions, stimulating economic development and increasing accessibility. Travelers can easily move between cities for work, leisure or other purposes.

[0014] Reducing Congestion: High-speed rail can help alleviate traffic congestion on highways and at airports by providing a convenient alternative for medium and long-distance travel.

[0015] Less Dependence on Air Travel: HSTs offer a sustainable alternative to domestic and regional air travel by reducing the need for short-distance flights and the associated environmental impacts.

[0016] High-speed trains represent an engineering masterpiece that combines advanced technology, infrastructure and design principles to provide fast, efficient and environmentally friendly transportation for passengers over long distances, providing benefits to both individuals and the environment. High Speed Railway: Sintered brake linings are used in high-speed railway systems where they must reliably slow and stop large trains travelling at high speeds.

[0017] Brake lining production using current technology cannot result in brake linings that offer outstanding performance, long life and reliability due to precise raw material selection, difficult braking applications.

[0018] Sintered linings used in high speed trains are imported from abroad. With this invention, these linings can be produced domestically and can be used for high speed trains.

[0019] The invention provides the development and production of high performance brake linings designed to fulfill stringent requirements such as friction coefficients, wear resistance, thermal conductivity, strength and environmental durability under varying operating conditions. It consists of auxiliary materials, lubricants, friction modifiers, abrasives, fillers with two different main raw material (1) structures namely Cu-Copper (A) and Cu-10Sn-Bronze (B).

[0020] The invention introduces a new approach to brake lining formulation and production, utilizing Cu-Copper and Cu-10Sn-Bronze formulas to form high performance brake linings with improved properties in a wide range of applications, particularly in the automotive sector.

[0021] The aim of this invention is related to the lack of production of brake linings for high speed trains (HSR) in our country by powder metallurgy and sinter metal technology. This study is the first study of brake lining manufacturing for high speed trains using powder metallurgy method, sinter metal technology metal powders.

[0022] The structural and characteristic features and all the advantages of the invention will be more clearly understood with the following detailed description, and therefore this evaluation should be made in consideration of this detailed description. SHORT DESCRIPTION OF THE FIGURE

[0023] Figure 1 : General view of sinter lining and production method for high-speed trains

[0024] REFERENCE NUMBERS GIVEN IN THE FIGURE

[0025] 1. Raw material

[0026] 2. Metal powder

[0027] 3. Mixing

[0028] 4. Pressing

[0029] 5. Sintering

[0030] DETAILED DESCRIPTION OF THE INVENTION

[0031] In this detailed description, the sinter lining and the production method for highspeed trains, which are the subject matter of the invention, are explained only with examples that will not have any limiting effect for a better understanding of the subject matter.

[0032] The invention focuses on the development and production of high-performance brake linings designed to meet stringent requirements such as friction coefficients, wear resistance, thermal conductivity, strength and environmental durability under varying operating conditions. The formula is obtained consisting of auxiliary materials, lubricants, friction modifiers, abrasives, fillers, with a structure of two different main raw materials (1 ) namely Cu-Copper (A) and Cu-10Sn-Bronze (B), each of which adds unique properties to the final product. It is to be able to prepare the production process stages that will realize the production of brake lining, production data in a way to give optimum results.

[0033] The invention uses 2 different formulations for sinter lining and production method (100 g) for high-speed trains, and the components used in the material by weight are as follows;

[0034] A: Cu - Copper-based raw material (1) formulation: • at the rate of 45-65% Cu,

[0035] • at the rate of 10-30% Fe,

[0036] • at the rate of 5-20% FeCr,

[0037] • at the rate of 5-20% Graphite,

[0038] • at the rate of 1 -7% M0S2,

[0039] • at the rate of 1 -7% AI2O3,

[0040] • at the rate of 1 -5% Zn2(Ci8H3sO2)2.

[0041] B: Cu - 10Sn-Bronze based raw material (1 ) formulation:

[0042] • at the rate of 45-65% Cu- 10Sn,

[0043] • at the rate of 10-30% Fe,

[0044] • at the rate of 5-20% Graphite,

[0045] • at the rate of 1 -7% M0S2,

[0046] • at the rate of 1 -7% AI2O3,

[0047] • at the rate of 1 -10% BaSC

[0048] • at the rate of 1 -5% Zn2(CisH35O2)2.

[0049] In the preferred embodiment of the invention, the subject matter of the invention is Cu 45 - 65 % and Cu-10Sn 45 - 65 % used in two different raw materials (1) mentioned above. These rates are the rates which give the most favorable results in terms of the desired properties of the product or end product brake lining.

[0050] Powder sizes are 5-10 pm for graphite and 325 mesh for others. Their purity is 99.9%.

[0051] These formulations are prepared to achieve optimum friction performance and durability under varying pressures, temperatures and operating speeds.

[0052] The production method of the product which is the subject of the invention comprises the following process steps. • Mixing (3) of raw materials A or B (1) with a suitable mixer (Turbulo 3V mixer) for 4 - 4.5 hours to obtain homogeneous mixtures of metal powders

[0053] (2),

[0054] • Determination of homogeneous mixing when the sample taken from the mixture is analyzed by XRF,

[0055] • Manufacturing of press molds made of steel for mold preparation and pressing of sample brake linings,

[0056] • Placing the metal powder (2) mixture (3) consisting of the raw materials (1 ) specified in A or B into the prepared pressing molds,

[0057] • Ensuring proper compression by pressing(4) the metal powder (2) mixture

[0058] (3) under controlled temperature and pressure conditions (300-450 MPa pressure at room temperature),

[0059] • Sintering (5) of pressed (4) metal powders (3) at predetermined temperatures and times (heating to 500°C at 10-15°C / min in a nitrogen atmosphere, waiting for 30 minutes - sintering at the same speed for 120 minutes at 1000°C for Cu-based (A) ones, sintering for 120 minutes at 800°C for Cu-10%Sn (B), cooling to room temperature at 10-15°C / min for both) under protective atmosphere gas pressure (sintering pressure 1000 mbar) for a predetermined time.

[0060] Thus, properties such as thermal conductivity, abrasion resistance, mechanical properties are increased. Friction coefficient is brought to appropriate values.

[0061] The coefficient of friction of the produced linings is 0.36 - 0.42; wear by mass is 0.56 - 0.88%; density is 4.6 - 5.42 gr / cm3; shear strength is 9.31 - 13.6 MPa.

[0062] The final product of the invention comprises combinations of raw materials A and B (1 ). Composite brake pads utilizing the properties of both Cu-Copper and Cu-10Sn- Bronze raw materials (1 ) are intended for use as high-performance brake linings.

[0063] In the preferred embodiment of the invention, the product or end product consisting of combinations A and B is used as a brake lining. The brake linings developed by the present invention are intended for use in a variety of applications, particularly in the automotive industry where reliable and high performance brake systems are required for safety and efficiency. These brake linings optimally meet the properties required from a brake lining, such as creating a suitable and stable friction coefficient at variable pressure, temperature and operating speeds, high wear resistance strength, high thermal conductivity, high strength properties, high thermal conductivity properties, high resistance to cracking and thermal fatigue, improved corrosive properties and minimum sensitivity to environmental conditions. The conditions (pressure, temperature, time, etc.) of the production method of the product which is the subject of the invention are also determined accordingly.

[0064] The invention introduces a new approach to brake lining formulation and production, utilizing Cu-Copper and Cu-10Sn-Bronze formulas to create high performance brake linings with improved properties for a wide range of applications, particularly in the automotive industry.

[0065] Each claim is followed by a reference number for all the technical and other features mentioned in each claim, and these reference numbers are used only to facilitate understanding of the claims and should not be considered for illustrative purposes as limiting the scope of any of the process steps indicated by these reference numbers.

[0066] It is clear that a person skilled in the art can also demonstrate the novelty set forth in the invention by using similar embodiments and / or apply this embodiment to other areas with similar purposes used in the relevant art. Therefore, it is also obvious that such embodiments will lack the criterion of novelty and especially the criterion of exceeding the state of the art.

Claims

CLAIMS1. Sinter lining for high-speed trains wherein it comprises the following materials; and characterized in that it comprises A: Cu - Copper-based raw material (1) formulation in 100 grams of material by weight:• at the rate of 45-65% Cu,• at the rate of 10-30% Fe,• at the rate of 5-20% FeCr,• at the rate of 5-20% Graphite,• at the rate of 1 -7% M0S2,• at the rate of 1 -7% AI2O3,• at the rate of 1 -5% Zn2(Ci8H3sO2)2.

2. Sinter lining for high-speed trains wherein it comprises the following materials; and characterized in that it comprises B: Cu-10Sn-Bronze based raw material (1 ) formulation in 100 grams of material by weight:• at the rate of 45-65% Cu- 10Sn,• at the rate of 10-30% Fe,• at the rate of 5-20% Graphite,• at the rate of 1 -7% M0S2,• at the rate of 1 -7% AI2O3,• at the rate of 1 -10% BaSC• at the rate of 1 -5% Zn2(CisH35O2)2.

3. Sinter lining production method for high-speed trains, wherein it comprises the following process steps:• Mixing (3) of raw materials A or B (1) with a suitable mixer (Turbulo 3V mixer) for 4 - 4.5 hours to obtain homogeneous mixtures of metal powders (2),• Determination of homogeneous mixing when the sample taken from the mixture is analyzed by XRF,• Manufacturing of press molds made of steel for mold preparation and pressing of sample brake linings,• Placing the metal powder (2) mixture (3) consisting of the raw materials (1 ) specified in A or B into the prepared pressing molds,• Ensuring proper compression by pressing(4) the metal powder (2) mixture (3) under controlled temperature and pressure conditions (300-450 MPa pressure at room temperature),• Sintering (5) of pressed (4) metal powders (3) at predetermined temperatures and times (heating to 500°C at 10-15°C / min in a nitrogen atmosphere, waiting for 30 minutes - sintering at the same speed for 120 minutes at 1000°C for Cu-based (A) ones, sintering for 120 minutes at 800°C for Cu-10%Sn (B), cooling to room temperature at 10-15°C / min for both) under protective atmosphere gas pressure (sintering pressure 1000 mbar) for a predetermined time.

4. Sinter lining for high speed trains according to any preceding claim, wherein it comprises high performance composite sinter lining which is composed of combinations of Cu-Copper or Cu-10Sn-Bronze formulations, which is capable of generating a suitable and stable coefficient of friction at the varying pressures, temperatures and operating speeds required from a brake lining and which has high wear resistance, high thermal conductivity, high strength properties.

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