Improvement of strength and wear resistance of stir cast SiCp/Al brake disc through friction stir processing

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear Pub Date : 2025-09-16 DOI:10.1016/j.wear.2025.206343

Kangxi Fu, Shiqi Zhang, Dong Tan, Jianyun Zhang, Hongmei Gao, Baowang Wang, Xiangping Li, Shaohua Xia

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引用次数: 0

Abstract

This study presents a hybrid manufacturing approach combining stir casting (SC) with friction stir processing (FSP) to produce high-performance SiCp/Al brake discs for high-speed commuter trains. This work is the first to apply FSP to full-size brake disc components and evaluate their tribological performance under simulated service conditions. The 20 vol% SiC-reinforced A356 alloy, initially fabricated by vacuum-assisted stir casting, exhibited typical casting defects such as porosity and particle agglomeration. These were effectively eliminated by surface FSP, which resulted in homogeneous SiC dispersion, refined microstructure, and improved interfacial bonding. Compared to SC discs, FSP discs demonstrate a significant increase in yield strength (196.8 MPa), ultimate tensile strength (219.6 MPa), and elongation (4.76 %), along with a 33 % reduction in wear loss. Moreover, the average friction coefficient of the FSP disc remains more stable across a range of braking speeds and pressures. These findings validate the feasibility of the proposed SC + FSP process as a scalable, lightweight, and durable solution for next-generation rail braking systems.

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通过搅拌摩擦工艺提高搅拌铸造SiCp/Al刹车盘的强度和耐磨性

提出了一种搅拌铸造（SC）与搅拌摩擦加工（FSP）相结合的混合制造方法，用于生产高速通勤列车用高性能SiCp/Al制动盘。这项工作是第一次将FSP应用于全尺寸制动盘部件，并在模拟使用条件下评估其摩擦学性能。采用真空辅助搅拌铸造法制备了20vol % sic增强A356合金，发现了典型的铸造缺陷，如气孔和颗粒团聚。表面FSP有效地消除了这些缺陷，使SiC分散均匀，微观结构精细，界面结合得到改善。与SC盘相比，FSP盘在屈服强度（196.8 MPa）、极限抗拉强度（219.6 MPa）和伸长率（4.76%）方面都有显著提高，同时磨损减少33%。此外，FSP圆盘的平均摩擦系数在制动速度和压力范围内保持更稳定。这些发现验证了SC + FSP工艺作为下一代铁路制动系统的可扩展、轻量化和耐用解决方案的可行性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Wear 工程技术-材料科学：综合

CiteScore

8.80

自引率

8.00%

发文量

280

审稿时长

47 days

期刊介绍： Wear journal is dedicated to the advancement of basic and applied knowledge concerning the nature of wear of materials. Broadly, topics of interest range from development of fundamental understanding of the mechanisms of wear to innovative solutions to practical engineering problems. Authors of experimental studies are expected to comment on the repeatability of the data, and whenever possible, conduct multiple measurements under similar testing conditions. Further, Wear embraces the highest standards of professional ethics, and the detection of matching content, either in written or graphical form, from other publications by the current authors or by others, may result in rejection.