High-wear-resistance Fe-Cu-based powder metallurgy composite material and preparation method thereof
Technical Field
The invention belongs to the technical field of powder metallurgy, and particularly relates to a high-wear-resistance Fe-Cu-based powder metallurgy composite material and a preparation method thereof.
Background
The powder metallurgy friction material is a composite material prepared by a powder metallurgy technology, wherein metal and alloy thereof are used as a matrix of the friction material, and then a friction component and a lubricating component are added. In actual production, iron-based and copper-based friction materials are widely applied, and other friction materials which are not commonly used, such as aluminum-based friction materials, nickel-based friction materials and the like, also exist. The powder metallurgy friction material has the following characteristics in general: the strength of the product can be satisfied, the product has stable and appropriate friction factor, small thermal expansion coefficient, stable and reliable performance during working, wear resistance and less pollution.
The iron-based powder metallurgy friction material takes iron powder as a main component, the melting point of iron is high, and the strength, hardness, plasticity, heat-resistant strength, oxidation resistance and the like of the iron can be adjusted by adding alloy elements. Compared with copper-based friction materials, the iron-based friction material is easier to bond, has larger friction factor variation, but has good high-temperature resistance and strength, strong pressure resistance, toughness and bearing capacity and better economy. The copper and copper alloy have better heat conductivity than iron and iron alloy, good oxidation resistance, higher strength and hardness and smaller intermiscibility with iron mating parts, so the copper-based friction pair has more stable joint and good wear resistance, but the friction coefficient stability under high load condition is poorer, and the price of copper is higher than that of iron.
The traditional means for improving the wear resistance of the material adopts a solid solution strengthening theory, and the solid solubility of Cu at 1300 ℃ is about 16%. Therefore, the Cu content added in the traditional Fe-based material is about 16 percent, but the improvement of the wear resistance of the material by only solid solution strengthening is not enough, and the simple addition of a small amount of Cu has the following defects:
1) the addition of a small amount of Cu cannot overcome the relatively large compatibility of Fe and a mating member thereof, the binary surface of the iron-based friction material is easily damaged in the braking process, and a deep or shallow groove is formed on the surface of the iron-based friction material, so that the change range of the friction coefficient of the material is large, and the instability or failure of braking is easily caused.
2) The material can produce huge heat in the braking process, the copper content is too little, the material has poor heat dissipation performance, the strength of the friction material can be greatly reduced, large abrasion loss is generated, and the friction stability and the service life of the friction material are influenced.
Therefore, it is necessary to research a new powder metallurgy composite material, which not only has the advantages of the copper-based friction material, but also has the advantages of the iron-based friction material, so as to meet the severe requirements of people on the comprehensive performance of the friction material in the modern industrial society.
Disclosure of Invention
In view of the above, the invention aims to provide a high wear-resistant Fe-Cu-based powder metallurgy composite material and a preparation method thereof, the composite material has the advantages of a copper-based friction material and the advantages of an iron-based friction material, and the Fe-Cu-based friction material overcomes the defects of adhesion of iron and a mating part thereof, high temperature instability of copper, large thermal expansion coefficient and the like, so that the Fe-Cu-based friction material has excellent wear resistance and great value for industrial application.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a high wear-resistant Fe-Cu-based powder metallurgy composite material is characterized in that: the alloy comprises the following components, by weight, 22-43% of Cu, 1-4% of Al, 2-4% of C, 1-2% of MnS and the balance Fe; the sum of the weight percentages of the components is 100 percent.
Part of Cu in the material is tightly combined with Fe tissues, so that the material has the effect of solid solution strengthening, the thermal expansion coefficient of copper is reduced, and the density and the wear resistance of the material are enhanced; the other part of Cu is also uniformly distributed on the Fe matrix to form a copper skeleton with fine grain size, so that the lubricating property of the material is enhanced, the heat conduction and the electric conductivity of the material are obviously improved. In addition, MnS in the invention can generate the effect of solid solution strengthening in the Fe-Cu-based friction material, C enables the material to form a solid lubricating carbon film on a grinding ring in the friction process, and FeC is formed in the combination with iron, so that the effect of solid solution strengthening is also realized, and the wear resistance of the material is improved together. Al is in liquid state during sintering and forms thin and dense Al at high temperature2O3The film is thin and is firmly combined with the substrate, thereby playing a role in reducing the friction coefficient.
Preferably, the alloy comprises the following components, by weight, 22% -33% of Cu, 2% -3% of Al, 2% -4% of C, 1% -2% of MnS and the balance Fe; the sum of the weight percentages of the components is 100 percent.
Preferably, the mass ratio of the Cu to the Fe is 0.30-0.82.
Preferably, the mass ratio of Cu to Fe is 0.59-0.82. The Cu net skeleton formed in the range of the ratio of Fe to Cu has finer grains, higher strength and higher heat dissipation rate, thereby having better wear resistance.
The invention also provides a method for preparing the high-wear-resistance Fe-Cu-based powder metallurgy composite material, wherein the sintering temperature of the composite material is 1086-1296 ℃, and the sintering time is 40-90 min.
The invention also provides the high wear-resistant Fe-Cu-based powder metallurgy composite material used in clutches or brakes of civil aircrafts, high-speed trains, wind power generation equipment and automobiles;
the composite material prepared by the preparation method is applied to clutches or brake devices of civil aircrafts, high-speed trains, wind power generation equipment and automobiles.
Compared with the prior art, the high-wear-resistance Fe-Cu-based powder metallurgy composite material and the preparation method thereof have the following advantages:
the Fe, Cu and C in the invention are distributed into blocks before sintering, and the structure distribution becomes compact after sintering at 1086-1296 ℃. Under the control of the mass ratio of Cu/Fe, the structures of Fe and Cu are tightly combined, and part of copper and iron form an iron-copper solid solution, so that the material is subjected to solid solution strengthening, the transformation of pearlite is promoted, the carburization process is promoted, the binding force between the structure interfaces is increased, the structure is more compact, the physical and mechanical properties of the powder metallurgy material are greatly enhanced, and the adhesion of iron and the high-temperature instability of copper are overcome; the other part of the copper powder is uniformly distributed on the Fe matrix to form a copper skeleton with fine grain size, so that the wear resistance of the material is enhanced.
C and a matrix structure generate certain structure transformation, a part of C is combined with Fe to form FeC, so that the solid solution strengthening effect is achieved, and the other part enables the material to form a solid lubricating carbon film on a grinding ring in the friction process, so that the friction coefficient of the material is reduced, and FeC exists on the surface of the matrix for a long time, the friction performance of the material can be improved, and the comprehensive performance of the material is promoted comprehensively.
In the composite material, S and Mn form a gap solid solution due to solid solution strengthening, so that the density and hardness of the composite material are enhanced, and the material has good heat resistance and friction performance. Al is in liquid state during sintering and forms thin and dense Al at high temperature2O3The film is thin, the wear resistance and the corrosion resistance of the surface of the matrix are enhanced, the combination with the matrix is firm, and the effect of reducing the friction coefficient is achieved.
The invention optimizes the matrix structure by reasonably controlling the proportion of Fe and Cu to each friction and lubrication component, and then cooperatively matches with a proper sintering process, so that the composite material has excellent friction and wear resistance and is suitable for industrial application.
Drawings
FIG. 1 is an X-ray diffraction diagram of an iron-copper based powder metallurgy material of example 2 of the present invention before sintering at 1191 ℃;
FIG. 2 is an X-ray diffraction pattern of the iron-copper based powder metallurgy material obtained in example 2 of the present invention after sintering at 1191 ℃;
FIG. 3 is a scanning electron microscope photograph of an iron-copper based powder metallurgy material according to example 5 of the present invention before sintering;
FIG. 4 is a scanning electron microscope photograph of an iron-copper based powder metallurgy material according to example 5 of the present invention after sintering;
FIG. 5 is a graph showing the change of the friction factor with time in example 1.
FIG. 6 is a graph showing the change of the friction factor with time in example 2.
FIG. 7 is a graph showing the change of the friction factor with time in example 3.
FIG. 8 is a graph showing the change in friction factor with time in example 4.
FIG. 9 is a graph showing the change in friction factor with time in example 5.
FIG. 10 is a graph showing the change in friction factor with time in example 6.
FIG. 11 is a graph showing the change of the friction factor with time in example 7.
FIG. 12 is a graph showing the change of friction factor with time of comparative example 1
Fig. 13 is a graph of the friction factor of comparative example 2 as a function of time.
Detailed Description
Unless defined otherwise, technical terms used in the following examples have the same meanings as commonly understood by one of ordinary skill in the art to which the present invention belongs. The test reagents used in the following examples, unless otherwise specified, are all conventional biochemical reagents; the experimental methods are conventional methods unless otherwise specified.
The present invention will be described in detail with reference to examples.
Example 1
A high-wear-resistance Fe-Cu-based powder metallurgy composite material is prepared from the following components in parts by weight: the Cu content is 22%, the Al content is 1%, the C content is 1.5%, the MnS content is 1.5%, and the balance is Fe, wherein the mass ratio of Cu to Fe is 0.30.
The sintering temperature is 1086 ℃, and the time is 55 min;
at a test pressure of 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.207, abrasion loss is: 0.0258 g.
Example 2
A high-wear-resistance Fe-Cu-based powder metallurgy composite material is prepared from the following components in parts by weight: the Cu content is 28%, the Al content is 1.4%, the C content is 2%, the MnS content is 2%, and the balance is Fe, wherein the mass ratio of Cu to Fe is 0.42.
The sintering temperature is 1121 ℃ and the time is 48 min;
at a test pressure of 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.172, abrasion loss: 0.0070 g.
Example 3
A high-wear-resistance Fe-Cu-based powder metallurgy composite material is prepared from the following components in parts by weight: the Cu content is 35%, the Al content is 1.8%, the C content is 2%, the MnS content is 2%, and the balance is Fe, wherein the mass ratio of Cu to Fe is 0.59.
The sintering temperature is 1156 ℃, and the time is 40 min;
at a test pressure of 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.141, abrasion loss: 0.0248 g.
The change in the friction coefficient of the iron-copper based material having a Cu content of 35% is shown in fig. 7.
Example 4
A high-wear-resistance Fe-Cu-based powder metallurgy composite material is prepared from the following components in parts by weight: the Cu content is 43%, the Al content is 1%, the C content is 2%, the MnS content is 1.5%, and the balance is Fe, wherein the mass ratio of Cu to Fe is 0.82.
Sintering at 1191 deg.C for 82 min;
at a test pressure of 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.152, the abrasion loss is: 0.0102 g.
Example 5
A high-wear-resistance Fe-Cu-based powder metallurgy composite material is prepared from the following components in parts by weight: the Cu content is 33%, the Al content is 4%, the C content is 3%, the MnS content is 1%, and the balance is Fe, wherein the mass ratio of Cu to Fe is 0.56.
The sintering temperature is 1226 ℃, and the time is 72 min;
at a test pressure of 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.123, the abrasion loss is: 0.0018 g.
Example 6
A high-wear-resistance Fe-Cu-based powder metallurgy composite material is prepared from the following components in parts by weight: the Cu content is 30%, the Al content is 1%, the C content is 2.5%, the MnS content is 1%, and the balance is Fe, wherein the mass ratio of Cu to Fe is 0.46.
The sintering temperature is 1261 ℃, and the time is 90 min;
at a test pressure of 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.129, abrasion loss: 0.0026 g.
Example 7
A high-wear-resistance Fe-Cu-based powder metallurgy composite material is prepared from the following components in parts by weight: the Cu content is 26%, the Al content is 2%, the C content is 2%, the MnS content is 2%, and the balance is Fe, wherein the mass ratio of Cu to Fe is 0.38.
Sintering at 1296 deg.C for 65 min;
the test pressure is 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.133, abrasion loss: 0.0031 g.
Comparative example 1
The powder metallurgy composite material comprises, by weight, 45% of Cu, 1% of Al, 2% of C, 2% of MnS and the balance Fe, wherein the mass ratio of Cu to Fe is 0.90.
Sintering at 1196 deg.C for 80 min;
at a test pressure of 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.446, the abrasion loss is: 0.0183 g.
Comparative example 2
The powder metallurgy composite material is prepared from the following components in parts by weight: the Cu content is 43%, the Al content is 3%, the C content is 1%, the MnS content is 2%, and the balance is Fe, wherein the mass ratio of Cu to Fe is 0.84.
Sintering at 1320 deg.C for 95min
At a test pressure of 2.9X 105The average friction coefficient is as follows after the pipe is in service for 15min under the condition that Pa and the rotating speed are 300 r/min: 0.311 wear loss is: 0.0241 g.
Attached table 1 is a table comparing the density, friction coefficient and wear level data of iron-copper based materials with different copper contents and sintering temperatures.
In examples and comparative examples, in which example 5 produced less ferrite, the pearlite content was the largest, and the interphalate spacing was the smallest, while the pearlite colony diameter was the largest at 1226 ℃; the density of the sample was: 6.386g/cm3The average friction coefficient is 0.123, and the abrasion loss is 0.0018 g; the friction factor is small and stable, and is therefore the best implementation case. While the average friction coefficients in comparative examples 1 and 2 were 0.446 and 0.311, respectively, which were the largest and less stable than the examples.
As can be seen from FIGS. 1 to 4, the structure of the material before sintering mainly comprises three phases of MnS, Cu and Fe, and the components of Fe and Cu are distributed in blocks and are not in close contact with each other. The aluminum powder and graphite are not uniformly mixed with the matrix structure, and the MnS powder is roughly distributed around the matrix structure, but does not form effective uniform distribution. Further, the sample had many and coarse voids, and the distribution of the respective components was very uneven. After sintering, the structure distribution of the sample becomes very compact, Mn and S elements in MnS are completely separated, Mn and S penetrate into a matrix to form a solid solution with iron, and the physical and mechanical properties of the material are enhanced through the solid solution strengthening effect. The sintered Al powder is transformed into compact Al from block2O3The film is present on the Fe-Cu matrix, so that the matrix is combined more firmly, and the corrosion resistance of the material is enhanced. And a part of C and Fe are combined to form FeC, so that the solid solution strengthening effect is achieved, and the other part of C exists in the form of a lubricating component C, so that the lubricating effect of the material is greatly improved. From the distribution condition of each component, under the control of the mass ratio of Cu/Fe, the structure of a part of Cu is continuously refined in the sintering process, the part of Cu is infiltrated into the iron matrix, the pores in the material are filled, and the part of Cu is occluded with the matrix structure after being cooled to form the Fe-Cu matrix, so that the solid solution strengthening effect is enhanced. The other part of the copper alloy is uniformly distributed on the Fe matrix to form a copper skeleton with fine grains, so that the friction performance of the material is greatly improved.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.