功能梯度复合材料制动盘设计及制备成形工艺、组织与性能研究
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摘要
颗粒增强金属基复合材料具有优良的性能,复合材料的制备技术和成形技术的研究已经引起人们的广泛关注,但是基于技术和成本方面考虑一直难以得到大范围的应用。由于颗粒增强金属基复合材料的性能受到具体的制备工艺技术、基体合金成分、增强颗粒的性质以及基体合金与增强颗粒的界面结合状况等诸多因素影响,现有的研究对这方面的认识还十分有限,数据资料也十分缺乏,在一定程度上也影响了颗粒增强金属基复合材料的推广应用。本论文从颗粒增强铝基复合材料新产品开发的需要出发,基于材料组成对产品进行设计,深入研究了颗粒增强复合材料的制备技术和离心铸造成形技术,对加工工艺方法对材料的组织、成分和性能特征影响进行了系统的研究,系统的阐述了复合材料制备和成形过程工艺-组织-性能特征。论文主要包括以下研究内容:
运用MSC.Patran有限元分析软件对不同材料的车辆用制动盘在同种工况条件下进行了热应力分析,结果表明颗粒增强铝复合材料颗粒体积分数沿径向具有梯度变化的制动盘热应力分布更为均匀,应力变化更为平缓,而且该种材料构成的制动盘具有减重和提高使用寿命的优点,实现了梯度功能复合材料制动盘材料构成的初步设计,提出了构建梯度复合材料制动盘的思想。
深入研究了重量达到32kg、体积分数为20%、平均粒径为15.8μm的SiC颗粒增强Zl104合金的复合材料制备技术,对搅拌复合过程的工艺参数、增强颗粒的分散过程进行了探讨。结合颗粒润湿机制对颗粒分散的动力学过程进行了研究,结果表明增强颗粒在熔体中的分散过程大致可以分为孕育期、聚集期和分散期三个阶段,加深了对复合铸造法制备颗粒增强复合材料的工艺过程认识。
对金属型铸造成形的20%SiCp/Zl104复合材料试样的微观组织结构、界面结合状况和机械性能进行了研究,表明复合材料界面结合良好,复合材料中增强颗粒聚集、孔隙率较高是造成材料力学性能较基体合金有所下降的主要原因。
对运用离心铸造成形方法制备的颗粒增强复合材料筒状件进行了系统的研究,结果表明,离心铸造工艺不仅会引起复合材料浆料中的增强颗粒分布、复合材料性质发生变化,而且由于凝固条件的变化也会使得构成复合材料的基体合金成分、微观组织结构在离心力方向产生变化,在对离心铸造成形过程中复合材料的凝固过程进行系统、深入探讨的基础上得出了离心铸造过程溶质传输、合金凝固过程的经验模型。
系统的研究了离心铸造成形的筒状件增强层和非增强层材料热处理工艺,探讨在热处理过程中材料的组织结构和力学性能特征,结果表明增强颗粒的添加是造成增强层材料热处理动力学加速的主要因素,非增强层的化学成分和组织结构变化提高了元素的扩散速度,起到了加速时效动力学的作用。
对基体合金材料、离心铸造成形的筒状件复合材料热处理前后的力学性能进行了深入探讨,结果表明增强颗粒的添加改变了材料的断裂模式,材料的断裂特征主要为增强颗粒引起的脆性断裂和基体合金的韧性断裂,复合材料整体表现为脆性断裂,由于基体合金与增强颗粒的界面处的位错密度较高、空位较多,在该处位错容易堆积形成裂纹断裂,铸态试样的力学性能不高,通过热处理方式可以有效的改善基体合金中的微观组织结构、降低界面处的位错密度和减少空位缺陷,其断裂主要表现为颗粒的脆性断裂,极大的提高了复合材料的布氏硬度和抗拉强度。
对基体合金材料、离心铸造成形的筒状件增强层材料热处理前后的磨损机制和耐磨损性能进行了深入研究,磨损试验是块体-GCr15轴承钢环试验机上无润滑的条件下进行的。结果表明材料的磨损主要表现为磨粒磨损、黏着磨损和疲劳磨损三种机制,这几种磨损机制经常伴生出现。铸态SiCp/Zl104复合材料试样的磨损主要表现为黏着磨损和疲劳磨损引起的块体剥落,此时SiC增强颗粒不是主要的载荷承受体,通过固溶处理之后,作为传递载荷的基体合金的塑性改善,主要表现为磨粒磨损,SiCp/Zl104复合材料试样耐磨损性能有极大的增加,而在进行了时效处理之后,主要表现为疲劳磨损。
采用立式离心铸造法完成了具有梯度变化复合材料盘状零件的试制备,结果表明合理的调整铸造工艺参数,调整复合材料的凝固时间和成形零件的凝固顺序,可以制备出SiC颗粒沿制动盘径向具有梯度分布的盘状零件,其硬度在径向方向也呈现梯度分布。
通过对复合材料设计、材料制备与成形的基础研究研究表明,实现梯度复合材料制动盘制备是可行的。通过该研究表明掌握材料制备与成形过程的规律,深入探讨材料制备与成形过程材料的组织-性能关系,将可有效的指导实际产品的开发。
The particle-reinforced metal matrix composites (PMMCs) has specific strength and stiffness and superior wear resistance, so many researchers and engineeres have focused on the fabrication and forming process of composites, but the widespread use of composite was limited for the consideration of technology and cast in the past. The mechanical properties of PMMCs are influenced by the fabrication process parameters, the properties of metal matrix and reinforced particles and interface structure between reinforced particles and metal matrix. But the connection between the properties and structure has not understood completely, and available data is so scarce that the application of composites is limited on a large scale. In this paper, the finite elements analysis (FEA) was applied to develop new product of PMMCs based on the constitutes in composites, the fabrication and centrifugal casting forming of particle-reinforced composites was researched deeply, and the effects of process parameters on the microstructure, composition and properties of composites is also researched systemically, and the characteristic of processing, microstructure and mechanical properties is illustrated widely. The main results are as following:
The temperature field and thermal stress field of brake disc with functional graded material (FGM) composites are researched under emergency braking by the finite element analysis (FEA) comparably, Attempts have been made to develop a novel brake disc, which can optimize brake’s working conditions. The results show that the temperature and thermal stress of FGM brake disc are the lowest among the three types of brake disc, and the distribution of temperature and thermal stress is also more uniform than the others. Furthermore, the FGM composite brake disc can decrease mass and increase life cycle. The primary design of FGM brake disc was carried out and refered to a new idea for the preparing of FGM brake disc.
The fabrication of SiC particle reinforced Zl104 composites is researched deeply, in which the volume fraction of SiC particles is 20 percent, and the average diameter is 15.8μm, and the mass of composites arrive to 32Kg in one cycle. The fabrication parameters and the mechanism of dispersing and wetting of SiC particles in aluminum alloy melt were discussed. The results showed that the dispersing of SiC particles in melt involves three stages, which are the incubation stage, the incorporation stage and the uniform stage based on the wettability of SiC particles. It is helpful for the further understood of the fabrication processing.
The microstructure, interface microstructure and mechanical properties of SiCp 20Vol.%/Zl104 composite samples were analyzed in detail. It is observed that there is no deleterious reaction in the interface between matrix alloy and SiC particle, and a little conglomeration of SiC particles and porosity are the main reasons for the decreasing of mechanical properties comparing to the matrix alloy.
The centrifugal casting processing of PMMCs cylinder (internal diameter is 70mm, outer diameter is 130mm and the height is 110mm) researched in detail. The results show that the distribution of SiC particles and constitution of composite material located in different location changed in the process of centrifugal casting, and the properties and microstructure were also influenced. And an experimental mode about solute transfer and alloy solidification under centrifugal force has been received.
The heat treatment processing of Zl104 alloy and the SiCp/Zl104 composites located in the reinforced zone and particle free zone of cylinder has been also researched based on the aging dynamics, and the microstructure and mechanical properties has been also discussed during heat treatment, results show that the adding of SiC particles has great effect on the heat treatment dynamics, the evolution of chemical composites and microstructure enhance the solute diffusion rate, so the the aging dynamic was shorted.
The mechanical properties and microstructure of Zl104 alloy and SiCp/Zl104 composites located in the reinforced zone of cylinder have been discussed before and after heat treatment. It is observed that the fracture of composites includes brittle fracture of SiC particles and tough fracture of matrix alloy, and the fracture of SiCp/Zl104 composites in whole is characterized as brittleness, the micro-void and dislocation density located in the interface lead to the fracture of matrix alloy ahead the fracture of SiC particles for the as casting samples, so the mechanical properties of samples decreases greatly comparing with the matrix alloy. After heat treatment processing, the microstructure of the matrix alloy in composites can be modified, and the local stress concentration and micro-void in alloy also can be reduced too, therefore, the fracture mode of samples is characterized as brittle facture of SiC particles, and the Brinell hardness and tensile strength of composites increase greatly compared with as casting sampes.
The wear behaviour and microstructural characterization of the wear surface of Zl104 alloy SiCp/Zl104 composites located in the reinforced zone of cylinder before and after heat treatment against GCr15 steel under unlubricated conditions using block-on-ring wear sliding wear tester.Results showed that the wear is charactered as grain abrasion, adhering abrasion and fatigue abrasion, and all of the wear mechanisms occurred at the same time. The wear behavior of as casting composites samples was mainly governed by the adhering abrasion and fatigue abrasion, in which the majority of SiC particles or precipitation of hard particles were fragmented and no longer acted as major load-bearing components. After solution treatment, the plastic of matrix alloy increase greatly, and the loading can transfer from SiC particles to the matrix, the wear behaviour of samples is charactered as grain abrasion. After aging treatment, the wear behaviour of samples is charactered as fatigue abrasion.
Composites discal part, in which the SiC particles have graded change along the diameter of the ring, has been accompleted. It is analyzed that the process parameters during centrifugal casting can be controlled by the adjustment of the solidification times and the solidification modes of SiCp/Al-Si composites, plated specimen with ideal distribution of SiC particles along the diameter of the plated part can be fabricated successfully, and the hardness along the diameter of the plated part is also change fuctionally.
The research on the constitution design, material fabrication and forming processing showed that it is feasible to preparing FGM’s production. The grasp of the fabrication of SiC 20%wt/Zl104 composites and the forming processing of FGM cylinder as well as plated part and the understanding of microstructure and mechanical properties will be an instruction for the development of FGM brake disc.
运用MSC.Patran有限元分析软件对不同材料的车辆用制动盘在同种工况条件下进行了热应力分析,结果表明颗粒增强铝复合材料颗粒体积分数沿径向具有梯度变化的制动盘热应力分布更为均匀,应力变化更为平缓,而且该种材料构成的制动盘具有减重和提高使用寿命的优点,实现了梯度功能复合材料制动盘材料构成的初步设计,提出了构建梯度复合材料制动盘的思想。
深入研究了重量达到32kg、体积分数为20%、平均粒径为15.8μm的SiC颗粒增强Zl104合金的复合材料制备技术,对搅拌复合过程的工艺参数、增强颗粒的分散过程进行了探讨。结合颗粒润湿机制对颗粒分散的动力学过程进行了研究,结果表明增强颗粒在熔体中的分散过程大致可以分为孕育期、聚集期和分散期三个阶段,加深了对复合铸造法制备颗粒增强复合材料的工艺过程认识。
对金属型铸造成形的20%SiCp/Zl104复合材料试样的微观组织结构、界面结合状况和机械性能进行了研究,表明复合材料界面结合良好,复合材料中增强颗粒聚集、孔隙率较高是造成材料力学性能较基体合金有所下降的主要原因。
对运用离心铸造成形方法制备的颗粒增强复合材料筒状件进行了系统的研究,结果表明,离心铸造工艺不仅会引起复合材料浆料中的增强颗粒分布、复合材料性质发生变化,而且由于凝固条件的变化也会使得构成复合材料的基体合金成分、微观组织结构在离心力方向产生变化,在对离心铸造成形过程中复合材料的凝固过程进行系统、深入探讨的基础上得出了离心铸造过程溶质传输、合金凝固过程的经验模型。
系统的研究了离心铸造成形的筒状件增强层和非增强层材料热处理工艺,探讨在热处理过程中材料的组织结构和力学性能特征,结果表明增强颗粒的添加是造成增强层材料热处理动力学加速的主要因素,非增强层的化学成分和组织结构变化提高了元素的扩散速度,起到了加速时效动力学的作用。
对基体合金材料、离心铸造成形的筒状件复合材料热处理前后的力学性能进行了深入探讨,结果表明增强颗粒的添加改变了材料的断裂模式,材料的断裂特征主要为增强颗粒引起的脆性断裂和基体合金的韧性断裂,复合材料整体表现为脆性断裂,由于基体合金与增强颗粒的界面处的位错密度较高、空位较多,在该处位错容易堆积形成裂纹断裂,铸态试样的力学性能不高,通过热处理方式可以有效的改善基体合金中的微观组织结构、降低界面处的位错密度和减少空位缺陷,其断裂主要表现为颗粒的脆性断裂,极大的提高了复合材料的布氏硬度和抗拉强度。
对基体合金材料、离心铸造成形的筒状件增强层材料热处理前后的磨损机制和耐磨损性能进行了深入研究,磨损试验是块体-GCr15轴承钢环试验机上无润滑的条件下进行的。结果表明材料的磨损主要表现为磨粒磨损、黏着磨损和疲劳磨损三种机制,这几种磨损机制经常伴生出现。铸态SiCp/Zl104复合材料试样的磨损主要表现为黏着磨损和疲劳磨损引起的块体剥落,此时SiC增强颗粒不是主要的载荷承受体,通过固溶处理之后,作为传递载荷的基体合金的塑性改善,主要表现为磨粒磨损,SiCp/Zl104复合材料试样耐磨损性能有极大的增加,而在进行了时效处理之后,主要表现为疲劳磨损。
采用立式离心铸造法完成了具有梯度变化复合材料盘状零件的试制备,结果表明合理的调整铸造工艺参数,调整复合材料的凝固时间和成形零件的凝固顺序,可以制备出SiC颗粒沿制动盘径向具有梯度分布的盘状零件,其硬度在径向方向也呈现梯度分布。
通过对复合材料设计、材料制备与成形的基础研究研究表明,实现梯度复合材料制动盘制备是可行的。通过该研究表明掌握材料制备与成形过程的规律,深入探讨材料制备与成形过程材料的组织-性能关系,将可有效的指导实际产品的开发。
The particle-reinforced metal matrix composites (PMMCs) has specific strength and stiffness and superior wear resistance, so many researchers and engineeres have focused on the fabrication and forming process of composites, but the widespread use of composite was limited for the consideration of technology and cast in the past. The mechanical properties of PMMCs are influenced by the fabrication process parameters, the properties of metal matrix and reinforced particles and interface structure between reinforced particles and metal matrix. But the connection between the properties and structure has not understood completely, and available data is so scarce that the application of composites is limited on a large scale. In this paper, the finite elements analysis (FEA) was applied to develop new product of PMMCs based on the constitutes in composites, the fabrication and centrifugal casting forming of particle-reinforced composites was researched deeply, and the effects of process parameters on the microstructure, composition and properties of composites is also researched systemically, and the characteristic of processing, microstructure and mechanical properties is illustrated widely. The main results are as following:
The temperature field and thermal stress field of brake disc with functional graded material (FGM) composites are researched under emergency braking by the finite element analysis (FEA) comparably, Attempts have been made to develop a novel brake disc, which can optimize brake’s working conditions. The results show that the temperature and thermal stress of FGM brake disc are the lowest among the three types of brake disc, and the distribution of temperature and thermal stress is also more uniform than the others. Furthermore, the FGM composite brake disc can decrease mass and increase life cycle. The primary design of FGM brake disc was carried out and refered to a new idea for the preparing of FGM brake disc.
The fabrication of SiC particle reinforced Zl104 composites is researched deeply, in which the volume fraction of SiC particles is 20 percent, and the average diameter is 15.8μm, and the mass of composites arrive to 32Kg in one cycle. The fabrication parameters and the mechanism of dispersing and wetting of SiC particles in aluminum alloy melt were discussed. The results showed that the dispersing of SiC particles in melt involves three stages, which are the incubation stage, the incorporation stage and the uniform stage based on the wettability of SiC particles. It is helpful for the further understood of the fabrication processing.
The microstructure, interface microstructure and mechanical properties of SiCp 20Vol.%/Zl104 composite samples were analyzed in detail. It is observed that there is no deleterious reaction in the interface between matrix alloy and SiC particle, and a little conglomeration of SiC particles and porosity are the main reasons for the decreasing of mechanical properties comparing to the matrix alloy.
The centrifugal casting processing of PMMCs cylinder (internal diameter is 70mm, outer diameter is 130mm and the height is 110mm) researched in detail. The results show that the distribution of SiC particles and constitution of composite material located in different location changed in the process of centrifugal casting, and the properties and microstructure were also influenced. And an experimental mode about solute transfer and alloy solidification under centrifugal force has been received.
The heat treatment processing of Zl104 alloy and the SiCp/Zl104 composites located in the reinforced zone and particle free zone of cylinder has been also researched based on the aging dynamics, and the microstructure and mechanical properties has been also discussed during heat treatment, results show that the adding of SiC particles has great effect on the heat treatment dynamics, the evolution of chemical composites and microstructure enhance the solute diffusion rate, so the the aging dynamic was shorted.
The mechanical properties and microstructure of Zl104 alloy and SiCp/Zl104 composites located in the reinforced zone of cylinder have been discussed before and after heat treatment. It is observed that the fracture of composites includes brittle fracture of SiC particles and tough fracture of matrix alloy, and the fracture of SiCp/Zl104 composites in whole is characterized as brittleness, the micro-void and dislocation density located in the interface lead to the fracture of matrix alloy ahead the fracture of SiC particles for the as casting samples, so the mechanical properties of samples decreases greatly comparing with the matrix alloy. After heat treatment processing, the microstructure of the matrix alloy in composites can be modified, and the local stress concentration and micro-void in alloy also can be reduced too, therefore, the fracture mode of samples is characterized as brittle facture of SiC particles, and the Brinell hardness and tensile strength of composites increase greatly compared with as casting sampes.
The wear behaviour and microstructural characterization of the wear surface of Zl104 alloy SiCp/Zl104 composites located in the reinforced zone of cylinder before and after heat treatment against GCr15 steel under unlubricated conditions using block-on-ring wear sliding wear tester.Results showed that the wear is charactered as grain abrasion, adhering abrasion and fatigue abrasion, and all of the wear mechanisms occurred at the same time. The wear behavior of as casting composites samples was mainly governed by the adhering abrasion and fatigue abrasion, in which the majority of SiC particles or precipitation of hard particles were fragmented and no longer acted as major load-bearing components. After solution treatment, the plastic of matrix alloy increase greatly, and the loading can transfer from SiC particles to the matrix, the wear behaviour of samples is charactered as grain abrasion. After aging treatment, the wear behaviour of samples is charactered as fatigue abrasion.
Composites discal part, in which the SiC particles have graded change along the diameter of the ring, has been accompleted. It is analyzed that the process parameters during centrifugal casting can be controlled by the adjustment of the solidification times and the solidification modes of SiCp/Al-Si composites, plated specimen with ideal distribution of SiC particles along the diameter of the plated part can be fabricated successfully, and the hardness along the diameter of the plated part is also change fuctionally.
The research on the constitution design, material fabrication and forming processing showed that it is feasible to preparing FGM’s production. The grasp of the fabrication of SiC 20%wt/Zl104 composites and the forming processing of FGM cylinder as well as plated part and the understanding of microstructure and mechanical properties will be an instruction for the development of FGM brake disc.
引文
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