표제지
목차
Abstract 13
Ⅰ. 서론 15
1. 연구 배경 15
2. 연구 필요성 16
Ⅱ. 이론적 배경 20
1. 브레이크 디스크의 개요 20
2. 브레이크 디스크 소재의 개요 25
2.1. 알루미늄 소재 27
2.2. 금속-세라믹 복합재료 28
2.3. 탄소-세라믹 브레이크 디스크 개발 29
3. 브레이크 디스크 국내외 기술 및 특허 동향 31
3.1. 기술 동향 31
3.2. 특허 동향 33
3.3. 심층분석 소결 39
4. 회주철 GC250 42
4.1. 회주철 GC250의 정의 42
4.2. 회주철 GC250의 기계적 성질 43
4.3. 회주철 GC250의 조직 44
4.4. 회주철의 분류 45
5. 회주철에 영향을 미치는 원소 49
5.1. 5대 원소가 주철에 미치는 영향 49
5.2. 합금원소가 주철에 미치는 영향 59
Ⅲ. 실험재료 및 방법 69
1. 연구 방법 69
1.1. 개요 69
1.2. 실험재료 77
2. 실험방법 79
2.1. 선진사 소재 성분 조성 분석 79
2.2. 선진사 소재 조직 구조 분석 82
2.3. 합금 설계 및 열처리 85
Ⅳ. 실험 결과 및 고찰 93
1. 합금 설계 93
2. 열처리 98
3. 질화 열처리 107
Ⅴ. 결론 115
참고문헌 116
〈Table 1〉 Brake disc material 26
〈Table 2〉 Set patent search conditions 34
〈Table 3〉 Patent search keyword summary 34
〈Table 4〉 Korea patents for brake disc technology 41
〈Table 5〉 Mechanical property for gray cast iron GC250 43
〈Table 6〉 Chemical composition and properties of foundary cast iron 46
〈Table 7〉 Alloy elements in gray cast iron 68
〈Table 8〉 Cr-alloy used in gray cast iron 68
〈Table 9〉 Chemical composition of GC250(JIS-FC250D) 70
〈Table 10〉 Chemical composition and physical properties of gray cast iron GC250 78
〈Table 11〉 Results of XRF composition analysis 80
〈Table 12〉 Results of ICP composition analysis 81
〈Table 13〉 Results of C/S composition analysis 81
〈Table 14〉 Composition of ferroalloy Fe-Cr 87
〈Table 15〉 Additional conditions of ferroalloy Fe-Cr 87
〈Table 16〉 Chemical composition of the cast design alloy 94
〈Table 17〉 Physical properties of the designed alloy 96
〈Table 18〉 Physical properties of the designed alloy after normalizing 106
〈Table 19〉 Physical properties of the design alloy after nitriding heat treatment 110
[Fig. 1] Model of Brake System. 16
[Fig. 2] Principles of disk brake operation. 22
[Fig. 3] Principles of drum brake operation. 22
[Fig. 4] Disk brake structure. 23
[Fig. 5] Vapor lock phenomenon. 24
[Fig. 6] Aluminum brake disc. 27
[Fig. 7] Aluminum ceramic composite drum brake. 28
[Fig. 8] Carbon-Ceramic brake disc. 30
[Fig. 9] Examples of ventilation disk(left) and regular disk(right). 31
[Fig. 10] Example of brake disc perforation. 32
[Fig. 11] Example of brake disc chaos groove processing. 32
[Fig. 12] Trend in applications by country. 35
[Fig. 13] Percentage of applications by country. 35
[Fig. 14] Number of applications by country (Cont'd). 37
[Fig. 15] Microstructure of gray cast iron GC250. 44
[Fig. 16] Mauer organization chart of cast iron. 50
[Fig. 17] Hardness of specimen according to P content. 56
[Fig. 18] Relation between tensile strength and P content. 57
[Fig. 19] Increase rate of tensile strength of cast iron according to alloying elements. 66
[Fig. 20] Alloy element factor diagram. 67
[Fig. 21] Alloy overall process. 71
[Fig. 22] Examples of structural deformation and recrystallization behavior of brake disc rotor products(Cont'd). 72
[Fig. 23] Examples of heat and post-treatment conditions for alloys for brake discs. 75
[Fig. 24] Equipment and measurement cases for evaluating the mechanical properties of alloys. 76
[Fig. 25] Microstructure of gray cast iron GC250. 77
[Fig. 26] XRD Pattern. 79
[Fig. 27] Microstructure of advanced material based on SEM analysis results. 83
[Fig. 28] Microstructure of advanced material based on EDS(line) analysis results. 84
[Fig. 29] Full experimental flow chart. 86
[Fig. 30] Design alloy manufacturing process. 88
[Fig. 31] Y-block. 89
[Fig. 32] 8A tension test specimen dimension of KS B 0801. 90
[Fig. 33] Rectangular tension test specimen of ASTM E8. 91
[Fig. 34] Test specimen for physical properties test. 92
[Fig. 35] Physical properties of the designed alloy. 95
[Fig. 36] Microstructure of Y-block. 97
[Fig. 37] Microstructure b efore heat treatment. 99
[Fig. 38] Microstructure after 2 hours of heat treatment. 100
[Fig. 39] Microstructure after 3 hours of heat treatment. 101
[Fig. 40] Microstructure after 4 hours of heat treatment. 102
[Fig. 41] Microstructure after 5 hours of heat treatment. 103
[Fig. 42] Microstructure after 8 hours of heat treatment. 104
[Fig. 43] Physical properties of the designed alloy after 8 hrs normalizing. 105
[Fig. 44] Tensile and hardness test specimen after nitriding heat treatment. 108
[Fig. 45] Physical properties of the design alloy after nitriding heat treatment. 109
[Fig. 46] Changes in physical properties of the designed alloy according to the amount of Cr added. 112
[Fig. 47] Microstructure after 5 hours of nitriding heat treatment(Con't). 113