Friction reducing coating

Abstract

A friction reducing coating includes an amorphous metal and a solid lubricant. The solid lubricant may be dispersed throughout the coating with the amorphous metal, or the solid lubricant may form a layer on top of the amorphous metal. The coating may be applied to various components, such as aircraft components, gas turbine engine components, and the like, to reduce friction.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to coating materials, coated substrates, textured surfaces, textured components, and methods of reducing friction generated by, for example, bearings, gears, bushings, or splined shafts in a gas turbine engine for an aircraft. BACKGROUND

[0002] Gas turbine engines include surfaces that are in mechanical contact with one another. The mechanical contact can generate friction, which reduces the performance of various systems, generates heat, and causes wear. BRIEF DESCRIPTION OF DRAWINGS

[0003] The features and advantages of the present disclosure will be apparent from the following detailed description of various exemplary embodiments, taken in conjunction with the accompanying drawings of which like reference numerals generally represent like structure, function, and / or operation.

[0004] Figure 1 is a schematic view of an aircraft having a gas turbine engine in accordance with embodiments of the present disclosure.

[0005] Figure 2 is Figure 1 is a cross-sectional view taken along line 2-2 in Figure 1 is a cross-sectional view taken along line 2-2 in

[0006] Figure 3 is a partial cross-sectional view of a bearing having a friction reducing coating and / or having a textured surface in accordance with embodiments of the present disclosure.

[0007] Figure 4 is a partial cross-sectional view of a bearing having a friction reducing coating and / or having a textured surface in accordance with embodiments of the present disclosure.

[0008] Figure 5 is a partial cross-sectional view of a journal bearing having a friction reducing coating and / or having a textured surface in accordance with embodiments of the present disclosure.

[0009] Figure 6 is a cross-sectional view of an squeeze film damper having a friction reducing coating and / or having a textured surface in accordance with embodiments of the present disclosure.

[0010] Figure 7 is a cross-sectional view of a mechanical seal having a friction reducing coating and / or having a textured surface in accordance with embodiments of the present disclosure.

[0011] Figure 8 is a partial cross-sectional view of a mechanical seal having a friction reducing coating and / or having a textured surface in accordance with embodiments of the present disclosure.

[0012] Figure 9is a partial cross-sectional view of a mechanical seal having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure.

[0013] Figure 10 is a schematic view of a spline shaft having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure.

[0014] Figure 11 is a schematic view of a gear having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure.

[0015] Figure 12A and Figure 12B shows friction and wear data for an uncoated disc and a disc coated with a friction reducing coating according to embodiments of the present disclosure. Figure 12A shows friction reduction data for a disc coated with a friction reducing coating according to embodiments of the present disclosure. Figure 12B shows wear reduction data for a disc coated with a friction reducing coating according to embodiments of the present disclosure.

[0016] Figure 13 shows friction reduction of a textured surface compared to a smooth surface. DETAILED DESCRIPTION

[0017] The features, advantages, and embodiments of the present disclosure are illustrated or described in or apparent from the following detailed description, drawings, and claims. Moreover, the following detailed description is exemplary and intended to provide further explanation of the application claimed and the following detailed description is not limiting.

[0018] Various embodiments are discussed in detail below. While specific implementations are discussed, this is simply for illustration. One skilled in the relevant art will recognize from the discussion that other components and configurations can be used without departing from the present disclosure.

[0019] The terms "forward" and "aft" refer to relative positions within a gas turbine engine or vehicle and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, with respect to a gas turbine engine, forward refers to a position closer to the engine inlet and aft refers to a position closer to the engine nozzle or exhaust.

[0020] The terms "upstream" and "downstream" refer to the relative direction with respect to the flow of fluid in a fluid path. For example, "upstream" refers to the direction from which fluid flows and "downstream" refers to the direction to which fluid flows. The term "fluid" can be a gas or a liquid. The term "fluid communication" means that a fluid can establish a connection between designated areas.

[0021] The terms “connection,” “fixation,” “attachment,” “linkage,” etc., refer to direct connection, fixation, attachment, or linking, as well as indirect connection, fixation, attachment, or linking through one or more intermediate parts or features, unless otherwise specified herein.

[0022] As used herein, an alloy is "based on" an element when that element is present in the alloy at the highest weight percentage (as a percentage of the total weight of the alloy) of all the elements contained in the alloy. For example, in an iron-based alloy, the weight percentage of iron is higher than the weight percentage of any other single element present in the alloy.

[0023] The singular forms “one,” “a,” and “the” include plural references unless the context clearly indicates otherwise.

[0024] Scope limitations may be combined and / or interchanged herein, as well as in this specification and claims. Unless the context or language otherwise indicates, such scopes are identified and include all subscopes contained herein. For example, all scopes disclosed herein include endpoints, and endpoints may be independently combined with each other.

[0025] As mentioned above, friction and wear can occur at mechanical contact points, such as between components in a gas turbine engine. For example, friction and wear can occur between bearings, seals, gears, and splined shafts. Friction and wear can degrade the performance of various systems and components, generate heat, and shorten the service life of components.

[0026] Friction-reducing coatings and / or textures can be applied to a wide variety of surfaces and components to reduce friction and wear. They can be applied to any surface or component that may be subjected to friction and / or wear, and are not limited to any particular application. Some non-limiting examples of suitable surfaces and components include: aircraft components, gas turbine engine components, rail vehicle components (e.g., bearings, gears, and / or shafts), automotive components (e.g., bearings, gears, and / or shafts), bearings (e.g., fan bearings, pitch bearings, and / or main module bearings), seals (e.g., carbon seals), gears (e.g., gearbox and / or transmission gears), and shafts (e.g., splined shafts). Some non-limiting examples relating to aircraft and / or gas turbine engines (e.g., gas turbines for aircraft, land-based gas turbine engines for power plants, and / or marine gas turbine engines for ships) are described in more detail below.

[0027] Figure 1 An aircraft 20, which can be implemented in various embodiments, is shown. The aircraft 20 includes a fuselage 22, wings 24 attached to the fuselage 22, and a tail 26. The aircraft 20 also includes a propulsion system that generates the thrust required to propel the aircraft 20 during flight, during taxiing operations, etc. Figure 1The propulsion system of the aircraft 20 shown includes a pair of engines 100. In this embodiment, each engine 100 is attached to one of the wings 24 by a pylon 28 in an underwing configuration. Although the engines 100 are shown as being in Figure 1 In the underwing configuration of the engine 24, the engine 100 is attached to the wing 24. However, in other embodiments, the engine 100 may have an alternative configuration and be coupled to other parts of the aircraft 20. For example, the engine 100 may additionally or alternatively include one or more aspects coupled to other components of the aircraft 20, such as the tail 26 and the fuselage 22.

[0028] The following text will refer to Figure 2 To be further described, Figure 1 The engine 100 shown is a gas turbine engine, each capable of selectively generating propulsive thrust for the aircraft 20. The amount of propulsive thrust can be controlled, at least in part, based on the volume of fuel supplied to the engine 100 (e.g., the gas turbine engine) via the fuel system 150. The aviation turbine fuel in the embodiments discussed herein is a combustible hydrocarbon liquid fuel, such as kerosene-type fuel with the desired carbon number, synthetic aviation fuel, biofuel, biodiesel, ethanol, bioalcohol, etc. The fuel is stored in a fuel tank 151 of the fuel system 150. Figure 1 As shown, at least a portion of the fuel tank 151 is located in each wing 24, and a portion of the fuel tank 151 is located in the fuselage 22, between the wings 24. However, the fuel tank 151 may be located in other suitable locations within the fuselage 22 or the wing 24. The fuel tank 151 may also be entirely located within the fuselage 22 or the wing 24. The fuel tank 151 may also be a separate tank, rather than a single integral unit, for example, two tanks each located within their respective wing 24.

[0029] Although Figure 1 The aircraft 20 shown is an airplane, but the embodiments described herein are also applicable to other aircraft 20, including, for example, helicopters and unmanned aerial vehicles (UAVs). The aircraft discussed herein are fixed-wing or rotary-wing aircraft that generate lift through aerodynamic forces acting on, for example, a fixed wing (e.g., wing 24) or a rotor (e.g., the rotor of a helicopter), and are heavier-than-air aircraft, rather than lighter-than-air aircraft (such as airships). Furthermore, although not described herein, in other embodiments, the gas turbine engine can be any other suitable type of gas turbine engine, such as an industrial gas turbine engine integrated into a power generation system, a marine gas turbine engine, etc.

[0030] Figure 2 It is used for Figure 1 A schematic cross-sectional view of one of the engines 100 used in the propulsion system of the aircraft 20 shown. Figure 2 Cross-sectional view alongFigure 1 line 2-2 taken in FIG. 1. For the embodiment shown, the engine 100 is a high-bypass engine. The engine 100 has an axial direction A (extending parallel to the longitudinal centerline axis 101 shown in FIG. 1 for reference), a radial direction R, and a circumferential direction. The circumferential direction (not shown in FIG. 1) extends in a direction of rotation about the axial direction A. The engine 100 includes a fan section 102 and a turbocharged engine 104 disposed downstream of the fan section 102. Figure 2 Figure 2 Figure 2

[0031] Figure 2 Figure 2

[0032] Figure 2 Figure 2 ​​​​​​As shown, the fan blades 128 extend generally in the radial direction R outward from the disk 130. In the case of a variable pitch fan, the plurality of fan blades 128 are rotatable relative to the disk 130 about a pitch axis P by virtue of the fan blades 128 being operably coupled to an actuation member 131 configured to collectively and uniformly change the pitch of the fan blades 128. The system for adjusting the pitch of the fan blades 128 can include one or more pitch bearings 145 to allow the fan blades 128 to rotate and change the pitch of the fan blades 128, and the one or more pitch bearings 145 can be coated with a friction reducing coating and / or have a textured surface to reduce friction. The fan blades 128, disk 130, and actuation member 131 are rotatable together about the longitudinal centerline axis 101 via a fan shaft 133, which is powered by the LP shaft 124 across a power gear box (also referred to as a gear box assembly 135). In this manner, the fan 126 is drivingly coupled to and powered by the turbocharged engine 104, and the engine 100 is an indirectly driven engine. The gear box assembly 135 can be a reduction gear box assembly for adjusting the rotational speed of the fan shaft 133, and thus the rotational speed of the fan 126 relative to the LP shaft 124, as power is transferred from the LP shaft 124 to the fan shaft 133. The gear box assembly 135 includes gears, and the gears can be coated with a friction reducing coating and / or have a textured surface to reduce friction.

[0033] Still referring to the exemplary embodiment of Figure 2 The disk 130 is covered by a fan hub 132 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 128. Further, the fan section 102 includes an annular fan casing or nacelle 134 that circumferentially surrounds the fan 126 and at least a portion of the turbocharged engine 104. The nacelle 134 is supported relative to the turbocharged engine 104 by a plurality of outlet guide vanes 136 circumferentially spaced about the nacelle 134 and the turbocharged engine 104. Further, a downstream section 138 of the nacelle 134 extends over an outer portion of the turbocharged engine 104 and defines a bypass airflow passage 140 therebetween with the outer casing 106.

[0034] During operation of the engine 100, a volume of air enters the turbine engine (e.g., engine 100) through an engine inlet 129 of the nacelle 134 or fan section 102. As the volume of air passes through the fan blades 128, a first portion of the air, also referred to as bypass air 137, is directed into the bypass airflow passage 140 and a second portion of the air, also referred to as core air 139, is directed into an upstream section of the core airflow path 121 through a core inlet 108 of the LP compressor 110. The ratio between the bypass air 137 and the core air 139 is commonly referred to as the bypass ratio. The pressure of the core air 139 is then increased in the compressor section 103, and more specifically, in the LP compressor 110, resulting in compressed air 141. The compressed air 141 is directed through the HP compressor 112 where it is further compressed and then into the combustion section 114 where it is mixed with fuel and ignited to produce combustion gases 143.

[0035] The combustion gases 143 are directed into and expanded through the HP turbine 116 where a portion of the thermal or kinetic energy from the combustion gases 143 is extracted via one or more stages of HP turbine stator vanes and HP turbine rotor blades coupled to the HP shaft 122. This causes the HP shaft 122 to rotate, supporting operation of the HP compressor 112 (self-sustaining cycle). In this manner, the combustion gases 143 do work on the HP turbine 116. The combustion gases 143 are then directed into and expanded through the LP turbine 118. Here, a second portion of the thermal or kinetic energy is extracted from the combustion gases 143 via one or more stages of LP turbine stator vanes and LP turbine rotor blades coupled to the LP shaft 124. This causes the LP shaft 124 to rotate, which supports operation of the LP compressor 110 (self-sustaining cycle) and rotation of the fan 126 via the gearbox assembly 135. In this manner, the combustion gases 143 do work on the LP turbine 118.

[0036] The combustion gases 143 are subsequently directed through the injection exhaust nozzle section 120 of the turbocharged engine 104 to provide propulsive thrust. At the same time, the bypass air 137 is directed through the bypass airflow passage 140 before being exhausted from the fan nozzle exhaust section of the engine 100, also providing propulsive thrust. The HP turbine 116, the LP turbine 118, and the injection exhaust nozzle section 120 at least partially define a hot gas path for directing the combustion gases 143 through the turbocharged engine 104.

[0037] Engine 100 can operate with, and receive a flow of fuel from, a fuel system 150. Fuel system 150 includes a fuel delivery assembly 153 that provides a flow of fuel from a fuel tank 151 to engine 100, and more specifically, to a plurality of fuel injectors 200 that inject fuel into combustion chambers of combustors of combustion section 114.

[0038] Components of fuel system 150, and more specifically, fuel tank 151, are one example of a fuel source that provides fuel to fuel injectors 200, as discussed in more detail below. Fuel delivery assembly 153 includes tubes, pipes, conduits, and the like, to fluidly connect various components of fuel system 150 to engine 100. Fuel tank 151 is configured to store a hydrocarbon fuel, and the hydrocarbon fuel is supplied from fuel tank 151 to fuel delivery assembly 153. Fuel delivery assembly 153 is configured to deliver the hydrocarbon fuel between fuel tank 151 and engine 100, thereby providing a flow path (fluid path) for the hydrocarbon fuel from fuel tank 151 to engine 100.

[0039] Fuel system 150 includes at least one fuel pump that is fluidly connected to fuel delivery assembly 153 to direct fuel through fuel delivery assembly 153 to engine 100. One such pump is a main fuel pump 155. Main fuel pump 155 is a high pressure pump that is a primary source of pressure rise in fuel delivery assembly 153 between fuel tank 151 and engine 100. Main fuel pump 155 can be configured to increase the pressure in fuel delivery assembly 153 to a pressure that is higher than the pressure within the combustion chambers of the combustors.

[0040] The fuel system 150 also includes a fuel metering unit 157 in fluid communication with the fuel delivery assembly 153. Any suitable fuel metering unit 157 can be used, including, for example, a metering valve. The fuel metering unit 157 is positioned downstream of the main fuel pump 155 and upstream of a fuel manifold 159, which is configured to distribute fuel to the fuel injectors 200. The fuel system 150 is configured to provide fuel to the fuel metering unit 157, and the fuel metering unit 157 is configured to receive fuel from the fuel tank 151. The fuel metering unit 157 is further configured to provide a flow of fuel to the engine 100 in a desired manner. More specifically, the fuel metering unit 157 is configured to meter fuel and provide a desired volume of fuel to the fuel manifold 159 of the engine 100 at, for example, a desired flow rate. The fuel manifold 159 is fluidly connected to the fuel injectors 200 and distributes (provides) the received fuel to the plurality of fuel injectors 200, where the fuel is injected into the combustion chambers and combusted. Adjusting the fuel metering unit 157 changes the volume of fuel provided to the combustion chambers, thereby changing the amount of propulsive thrust generated by the engine 100 to propel the aircraft 20.

[0041] The engine 100 also includes various accessory systems to aid in the operation of the engine 100 and / or an aircraft that includes the engine 100. For example, the engine 100 can include a main lubrication system 162, a compressor cooling air (CCA) system 164, an active thermal clearance control (ATCC) system 166, and a generator lubrication system 168. The main lubrication system 162 is configured to provide lubricant to various bearings and gear meshes in, for example, the compressor section, the turbine section, the HP shaft 122, and the LP shaft 124. The lubricant provided by the main lubrication system 162 can increase the useful life of these components, and can remove an amount of heat from these components through the use of one or more heat exchangers. The compressor cooling air (CCA) system 164 provides air from one or both of the HP compressor 112 or the LP compressor 110 to one or both of the HP turbine 116 or the LP turbine 118. The active thermal clearance control (ATCC) system 166 functions to minimize the clearance between the tips of the turbine blades and the casing wall as the casing temperature changes during a flight mission. The generator lubrication system 168 provides lubrication for an electronic generator (not shown) and provides cooling / heat dissipation for the electronic generator. The electronic generator can provide power for, for example, a starter motor for the engine 100 and / or various other electronic components of the engine 100 and / or an aircraft that includes the engine 100. The lubrication systems for the engine 100 (e.g., the main lubrication system 162 and the generator lubrication system 168) can use a hydrocarbon fluid (e.g., oil) for lubrication, where the oil circulates through the interior surfaces of the oil scavenge lines.

[0042] The engine 100 discussed herein is provided as an example only. In other embodiments, any other suitable engine can be used with aspects of the present disclosure. For example, in other embodiments, the engine can be any other suitable gas turbine engine, such as a turboshaft engine, a turboprop engine, a turbojet engine, a ductless single fan engine, or the like. In this way, in other embodiments, the gas turbine engine can have other suitable configurations, such as a direct drive configuration, a fixed pitch fan, or other suitable number or arrangement of shafts, compressors, turbines, fans, and the like. Moreover, although the engine 100 is depicted as a turbofan engine, aspects of the present disclosure can be used with other types of engines, such as reciprocating engines, or the like. Additionally, in other example embodiments, the example engine 100 can include or be operatively connected to any other suitable accessory system. Additionally or alternatively, the example engine 100 can not include or be operatively connected to one or more of the accessory systems 162, 164, 166, and 168 described above. Figure 2 Although a particular engine 100 is depicted in the foregoing discussion, the friction reducing coating and / or textured surface can be used more broadly and / or with other engine embodiments. For example, in alternative embodiments, aspects of the present disclosure can be incorporated into or otherwise used with any other type of engine (e.g., a reciprocating engine). Moreover, in other example embodiments, the example engine 100 can include or be operatively connected to any other suitable accessory system. Additionally or alternatively, the example engine 100 can not include or be operatively connected to one or more of the accessory systems 162, 164, 166, and 168 described above.

[0043] The foregoing discussion is provided by way of example only, and the friction reducing coating and / or textured surface can be applied to any component that experiences friction under normal operation, such as a bearing, a seal, a gear, and / or a shaft. For example, the friction reducing coating and / or textured surface can be applied to a substrate that is a bearing raceway, an extrusion film damper, a ball of a ball bearing, a conical roller of a roller bearing, a cylindrical roller of a roller bearing, a journal bearing component, or a needle roller of a roller bearing. Some additional non-limiting examples of such components are shown in FIGS. 3 through 6. Figure 11 As discussed below.

[0044] Figure 3 is a partial cross-sectional view of a bearing having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure. Figure 3 A main module bearing 300 is shown. The main module bearing 300 facilitates motion between two components, such as a static component 310 and a rotating component 320. For example, the main module bearing 300 can support the fan shaft 133 Figure 2 as the rotating component 320. The main module bearing 300 can be the front bearing 119 Figure 2 or the rear bearing 123 that supports the HP shaft 122 Figure 2 as the rotating component 320. The main module bearing 300 can be the front bearing 125 Figure 2 or the rear bearing 127 Figure 2 that supports the LP shaft 124 Figure 3The bearing shown in FIG. 1 is a roller bearing having a roller 302. The roller 302 includes an end 304 and a shoulder 306. Figure 3 The roller 302 shown in FIG. 1 is a cylindrical roller, more specifically a round cylindrical roller, but the roller 302 can have other suitable shapes including, for example, a ball, a needle, a tapered roller, or a convex roller. The roller 302 is in contact with a first bearing portion 308 (attached or otherwise connected to the rotating component 320) and a second bearing portion 309 (attached or otherwise connected to the static component 310). One or both of the first bearing portion 308 and the second bearing portion 309 can include a raceway in which the roller 302 can move. In Figure 3 In the embodiment shown, the first bearing portion 308 includes a raceway that is a groove formed in the first bearing portion 308. The first bearing portion 308 and the second bearing portion 309 sandwich the roller 302. As described above, the rotating component 320 is connected to or otherwise in contact with the main module bearing 300, and the main module bearing 300 facilitates rotation of the rotating component 320 through movement of the roller 302 along the raceway. Any surfaces in the main module bearing 300 that experience friction under normal operation can be coated with a friction-reducing coating and / or have a textured surface to reduce friction and / or wear at the surface. For example, one or more surfaces of the roller 302 (such as the end 304 and / or the shoulder 306) can be coated with a friction-reducing coating and / or have a textured surface to reduce friction and / or wear at the surface. Likewise, one or more contact surfaces of the first bearing portion 308 (such as the raceway) and the second bearing portion 309 can be coated with a friction-reducing coating and / or have a textured surface to reduce friction and / or wear at the surface. The main module bearing 300 can be, for example, a subassembly of any of the components disclosed herein having a bearing (such as the front bearing 119, the rear bearing 123, the front bearing 125, the rear bearing 127, and / or the pitch bearing 145). For example, the bearing can be a main module bearing such that the rotating component 320 is the HP shaft 122 or the LP shaft 124.

[0045] Figure 4 is a partial cross-sectional view of a bearing having a friction-reducing coating and / or a textured surface according to embodiments of the present disclosure. Figure 4 A pitch bearing 400 having a roller 302 is depicted. For example, the pitch bearing 400 can be like Figure 2 the pitch bearing 145 shown in FIG. 1 supporting the fan blades 128. The roller 302 includes an end 304 and a shoulder 306. Figure 4 The roller 302 shown in FIG. 1 is a tapered roller having a tapered diameter along a length of the roller 302. Figure 3 The discussion of the main module bearing 300 in FIG. 1 applies equally to Figure 4A pitch bearing 400 is shown. The pitch bearing 400 can be, for example, a subassembly of any component disclosed herein having a bearing (e.g., the pitch bearing 145) with a friction reducing coating and / or having a textured surface.

[0046] Figure 5 is a partial cross-sectional view of a journal bearing having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure. Figure 5 A journal bearing assembly 500 is shown. The journal bearing assembly 500 has a journal bearing housing 502 that includes a bushing or sleeve 504 in contact with a shaft 506. The bushing or sleeve 504 has a contact area 508 for contacting a surface 510 of the shaft 506. The shaft 506 can rotate within the journal bearing assembly 500 about a longitudinal axis, which can cause friction between the contact area 508 and the surface 510. The contact area 508 and / or the surface 510 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with movement (e.g., rotational movement) of the shaft 506 relative to the journal bearing housing 502. The journal bearing assembly 500 can be, for example, a subassembly of any component disclosed herein having a journal bearing, including, for example, an extrusion film damper or a reduction gear box.

[0047] Figure 6 is a cross-sectional view of an extrusion film damper having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure. Figure 6 A bearing assembly 600 is depicted. The bearing assembly 600 has an extrusion film damper 602 between a housing component 604 and a bearing component 606. The extrusion film damper 602 can be effective for dampening unwanted vibrations that can occur during operation of the bearing assembly 600 by, for example, providing viscous damping of unwanted vibrations. Rotational movement of the bearing component 606 can also cause friction at one or more surfaces 608 of the extrusion film damper 602 during normal operation of the bearing assembly 600. The one or more surfaces 608 of the extrusion film damper 602 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with movement of the bearing component 606 relative to the extrusion film damper 602. The bearing assembly 600 can be, for example, a subassembly of any component disclosed herein having a bearing (e.g., the front bearing 119, the rear bearing 123, the front bearing 125, the rear bearing 127, and / or the pitch bearing 145) with a friction reducing coating and / or having a textured surface. Figure 4 The front bearing 119, the rear bearing 123, the front bearing 125, the rear bearing 127, and / or the pitch bearing 145) disclosed herein.

[0048] Figure 7 is a cross-sectional view of a mechanical seal having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure. Figure 7A first mechanical seal assembly 700 is depicted. As discussed above, the friction reducing coatings and / or textured surfaces discussed herein can be applied to any surface that generates friction during normal operation. Mechanical seal assemblies, such as the first mechanical seal assembly 700 shown, include such surfaces. The first mechanical seal assembly 700 includes a stator, such as a stationary housing 702, and a rotor, for example a seal runner 710 connected to a shaft 712. A seal is formed between the stationary housing 702 and the shaft 712. The stationary housing 702 includes a seal element 704 having a contact area 706. The seal runner 710 has a surface 708 for contacting the contact area 706 of the seal element 704. The contact area 706 and / or the surface 708 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with the sliding motion of the seal runner 710 relative to the seal element 704. The seal runner 710 can be in contact with the shaft 712, which can drive the sliding motion of the seal runner 710 relative to the seal element 704. The seal element 704 can be, for example, a carbon seal. The first mechanical seal assembly 700 can be, for example, a subassembly of any of the components having a mechanical seal disclosed herein. Figure 7 The first mechanical seal assembly 700 includes a stator, such as a stationary housing 702, and a rotor, for example a seal runner 710 connected to a shaft 712. A seal is formed between the stationary housing 702 and the shaft 712. The stationary housing 702 includes a seal element 704 having a contact area 706. The seal runner 710 has a surface 708 for contacting the contact area 706 of the seal element 704. The contact area 706 and / or the surface 708 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with the sliding motion of the seal runner 710 relative to the seal element 704. The seal runner 710 can be in contact with the shaft 712, which can drive the sliding motion of the seal runner 710 relative to the seal element 704. The seal element 704 can be, for example, a carbon seal. The first mechanical seal assembly 700 can be, for example, a subassembly of any of the components having a mechanical seal disclosed herein.

[0049] Figure 8 A partial cross-sectional view of a mechanical seal having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure. Figure 8 A second mechanical seal assembly 800 is depicted, which includes a stationary housing 702 for a seal element 704 in contact with a seal runner 710. More specifically, the seal element 704 has a contact area 706 in contact with a surface 708 of the seal runner 710. The contact area 706 and / or the surface 708 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with the sliding motion of the seal runner 710 relative to the seal element 704. The seal element 704 can be, for example, a seal comprising or consisting of carbon (i.e., a carbon seal). The second mechanical seal assembly 800 can be, for example, a subassembly of any of the components having a mechanical seal disclosed herein.

[0050] Figure 9 A partial cross-sectional view of a mechanical seal having a friction reducing coating and / or having a textured surface according to embodiments of the present disclosure. Figure 9 A radial seal assembly 900 is shown, which includes a stationary housing 702 for a seal element 704 in contact with a seal runner 710. More specifically, the seal element 704 has a contact area 706 in contact with a surface 708 of the seal runner 710. Figure 9The illustrated radial seal assembly includes a tooth 904 that contacts a surface 708 of the seal runner 710. The tooth 904 is formed on a sealing face 906 of the seal body 908 and extends from the sealing face 906 toward the seal runner 710. The contact area 706 and / or the tooth 904 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with sliding motion of the seal runner 710 relative to the seal element 704 and / or the tooth 904. Additionally and / or alternatively, the surface 708 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with sliding motion of the seal runner 710 relative to the seal element 704 and / or the tooth 904. The seal runner 710 can be, for example, a carbon seal. The radial seal assembly 900 can be, for example, a subassembly of any of the components disclosed herein having a radial seal.

[0051] Figure 10 is a schematic illustration of a spline shaft having a friction reducing coating and / or a textured surface according to embodiments of the present disclosure. Figure 10 A spline shaft assembly 1000 is depicted. As discussed above, the friction reducing coatings and / or textured surfaces discussed herein can be applied to any surface that generates friction during normal operation. Spline assemblies, such as Figure 10 The illustrated spline shaft assembly 1000, spline board assembly, or spline plate assembly includes such surfaces. Figure 10 The illustrated spline shaft assembly includes an inner shaft 1002 with splines (referred to as inner splines 1004) and an outer shaft 1006 with splines (referred to as outer splines 1008). In Figure 10 In the illustrated spline shaft assembly 1000, the outer shaft 1006 has a bore, and the outer splines 1008 are formed on the bore surface 1010 and project inwardly toward the bore. Likewise, the inner shaft 1002 has an outer surface 1012, and the inner splines 1004 are formed on the outer surface 1012 and project outwardly from the inner shaft 1002. The inner shaft 1002 contacts the outer shaft 1006, and the inner splines 1004 engage the outer splines 1008 such that rotational motion of the inner shaft 1002 or the outer shaft 1006 causes rotational motion of the outer shaft 1006 or the inner shaft 1002, respectively. The inner splines 1004 of the inner shaft 1002 and / or the outer splines 1008 of the outer shaft 1006 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with motion of the inner shaft 1002 and / or the outer shaft 1006. The spline shaft assembly 1000 can be, for example, a subassembly of any of the components disclosed herein that include a spline shaft.

[0052] Figure 11 is a schematic illustration of a gear having a friction reducing coating and / or a textured surface according to embodiments of the present disclosure. Figure 11A gear assembly 1100 is depicted. The gear assembly includes a first gear 1102 and a second gear 1108. The first gear 1102 has a toothed portion 1104 and the second gear 1108 has a toothed portion 1106. The toothed portion 1104 of the first gear 1102 contacts the toothed portion 1106 of the second gear 1108 such that rotational motion of the first gear 1102 or the second gear 1108 causes rotational motion of the second gear 1108 or the first gear 1102, respectively. The toothed portion 1104 of the first gear 1102 and / or the toothed portion 1106 of the second gear 1108 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with the motion of the first gear 1102 and / or the second gear 1108. The gear assembly 1100 can be a subassembly of, for example, any of the components disclosed herein, such as the gear box assembly 135.

[0053] The foregoing discussion is merely by way of example, and the friction reducing coating and / or textured surface can be applied to any substrate that can experience friction and / or wear. A coated component is any component that includes a substrate coated with a friction reducing coating, such as the bearings, gears, splines, and seals discussed above. For example, the substrate can be a metal substrate, a ceramic substrate, a carbon-based substrate, a metal substrate coated with a ceramic layer, a ceramic substrate coated with a metal layer, a metal substrate coated with a carbon-based layer, or a ceramic substrate coated with a carbon-based layer. The metal substrate can include, for example, a ferrous alloy, a nickel-based alloy, a cobalt-based alloy, an alloy containing cobalt and chromium, an alloy containing platinum and aluminum, an alloy containing nickel and aluminum, or an alloy containing nickel, chromium, aluminum, and yttrium.

[0054] A fluid lubricant, such as oil, grease, mineral oil, synthetic oil, or any other liquid hydrocarbon, can be applied to any surface that generates friction during normal operation, for example, to dissipate heat from hot metal components and to reduce friction. The inventors have unexpectedly discovered that a coating including amorphous metal and solid lubricant dispersed throughout the coating can reduce friction between surfaces even in the absence of a fluid lubricant. In some embodiments, the coated component is free of a fluid lubricant. The absence of a fluid lubricant can further improve the friction reducing effects of the coating, for example, by reducing viscous losses associated with the flow of a fluid lubricant during use. The inventors have also unexpectedly discovered that a textured surface can reduce friction as compared to a smooth surface. Without wishing to be bound by theory, a textured surface can trap lubricant (e.g., a fluid lubricant) near the textured surface, thereby reducing friction at the textured surface. These discoveries can be combined, for example, by texturing a surface of a coating including amorphous metal and solid lubricant and / or texturing a surface that contacts a coating including amorphous metal and solid lubricant.

[0055] Without wishing to be bound by theory, it is believed that the amorphous structure of the metal improves the friction reducing effect compared to a more crystalline metal coating. Further, it is believed that the dispersion of the solid lubricant throughout the amorphous metal of the coating provides an enhanced friction reducing effect by, for example, providing the solid lubricant at the surface of the coating and at contact points within the coating as the coating deforms and / or wears during use. The solid lubricant can be dispersed in the amorphous metal in the form of discrete particles by co-deposition with the bulk metallic glass (by, for example, thermal spraying). After thermal spraying, the solid lubricant can migrate to microstructural regions of the coating.

[0056] As discussed in more detail below, the coating component can have a dry sliding coefficient of friction greater than zero and less than 0.6, for example, when the coating is sliding on a steel disc.

[0057] The composition of the amorphous metal is not particularly limited. Some examples include an amorphous iron-based metal, an amorphous nickel-containing alloy, an amorphous molybdenum-based alloy, a niobium-containing amorphous metal, and an amorphous steel. In some embodiments, the amorphous metal comprises at least one of iron, chromium, molybdenum, cobalt, nickel, tungsten, boron, manganese, carbon, or silicon. In some embodiments, the amorphous metal is an iron-based alloy comprising at least two of chromium, molybdenum, tungsten, boron, manganese, carbon, or silicon. In some embodiments, the amorphous metal is an iron-based alloy comprising at least three of chromium, molybdenum, tungsten, boron, manganese, carbon, or silicon, and an iron-based alloy comprising at least three of chromium, molybdenum, tungsten, boron, manganese, carbon, or silicon. In some embodiments, the amorphous metal is an iron-based alloy, a nickel-based alloy, a cobalt-based alloy, a chromium-based alloy, or a molybdenum-based alloy.

[0058] The composition of the solid lubricant is not particularly limited. Some examples include tungsten disulfide, tantalum disulfide, hexagonal boron nitride, molybdenum disulfide, graphite, tungsten oxide, boron oxide, nickel oxide, talc, polytetrafluoroethylene, or combinations thereof. The solid lubricant can be included in the coating in any amount. For example, the amount of solid lubricant in the coating can range from 1 wt% to 30 wt% of the total weight of the coating. The amount of solid lubricant can vary based on, for example, the coating friction and the coating wear.

[0059] The thickness of the friction reducing coating is not particularly limited. A suitable coating thickness can be determined based on, for example, the composition of the component, the expected contact force between components, and the like, to account for, for example, the wear rate of the friction reducing coating. For example, the thickness of the friction reducing coating can range from 0.1 micrometers to 300 micrometers, or any sub-range contained therein. For example, the thickness of the friction reducing coating can range from 100 micrometers to 200 micrometers. A thickness ranging from 100 micrometers to 200 micrometers can ensure the longevity of the coating throughout the service life of the component while the coating experiences wear.

[0060] The inventors have unexpectedly discovered that textured surfaces can reduce friction when the textured surface is in contact with a contact surface. Any of the surfaces disclosed above can be textured to reduce friction, including, for example, the friction reducing coatings and / or surfaces for contact friction reducing coatings discussed above. For example, any surface on a component disclosed above can include a textured surface and a contact surface. Components that include a textured surface and a contact surface are referred to herein as textured components. The texture can be used in conjunction with a lubricant to reduce friction by, for example, capturing the lubricant near the textured surface.

[0061] The inventors have unexpectedly discovered that surfaces with a roughness greater than 0.05 microns and less than 2 microns (e.g., greater than 0.05 microns and less than 0.5 microns) have a reduced coefficient of friction compared to smoother surfaces. Surface roughness can be determined by, for example, a contact profilometer or a non-contact profilometer. In some embodiments, the surface roughness of the friction reducing coating and / or surfaces for contact friction reducing coatings is greater than 0.05 microns and less than 2 microns. In some embodiments, the surface roughness of the friction reducing coating and / or surfaces for contact friction reducing coatings is greater than 0.05 microns and less than 0.5 microns. The surface roughness can be tailored according to the size characteristics of the texture. For example, texture features with a size greater than 2 microns can have a surface roughness greater than 0.05 microns and less than 0.5 microns, selected based on a variety of factors such as oil viscosity, surface energy, texture feature radius, and texture feature spacing. The inventors have unexpectedly discovered that surfaces with roughness in these ranges have a reduced coefficient of friction compared to smoother surfaces.

[0062] In evaluating changes that can occur in a design, the inventors have unexpectedly discovered a relationship between selected features of a textured component that results in an effect superior to a number of other designs considered. The inventors refer to this relationship as the texture factor. The texture factor is defined by (A1 / A2)*(Ra1 / Ra2)*thickness, where a texture factor in the range of 0.01 to 0.75 has an unexpectedly reduced coefficient of friction compared to surfaces with texture factors outside of this range. In the definition of the texture factor, A1 is the area of the textured surface (which can be, for example, the surface of a gear tooth (e.g., 1104 of FIG. 1) or the surface of a bearing (e.g., 308 or 309 of FIG. 3)), and A2 is the area of the contact surface that contacts the textured surface (e.g., the surface of the tooth tip and tooth root of a gear tooth (e.g., 1106 of FIG. 1) or the entire bearing surface (e.g., 308 or 309 of FIG. 3)). Figure 11 Figure 3 Figure 4 Figure 11 Figure 3 Figure 4 ​​​​​A1 / A2, Ral is the surface roughness of the textured surface, Ra2 is the surface roughness of the contact surface (e.g., a gear meshing surface or a non-textured surface), and thickness is the thickness of the oil film in contact with the textured surface. In some embodiments, the area ratio A1 / A2 ranges from 0.2 to 0.3. In some embodiments, Ral ranges from 0.1 microns to 5 microns. In some embodiments, Ra2 ranges from 0.1 microns to 0.3 microns. In some embodiments, the contact surface is not textured. In some embodiments, the thickness of the oil film in contact with the textured surface ranges from 0.05 millimeters to 0.2 millimeters. In some embodiments, the texture size ranges from 100 nanometers to 1000 nanometers. In some embodiments, the texture size ranges from 1 microns to 100 microns. The texture size can be a sub-micron or micron scale feature that covers the surface dimension of the texture. Any of the disclosed surfaces can be textured with a texture factor ranging from 0.01 to 0.75 to reduce friction, including, for example, the friction reducing coatings and / or surfaces for contact friction reducing coatings discussed above. For example, referring again to Figure 11 One or more surfaces 608 of the squeeze film damper 602 can be coated with a friction reducing coating and / or have a textured surface to reduce friction and / or wear associated with movement of the bearing component 606 relative to the squeeze film damper 602, and in some embodiments, the friction reducing coating has a texture factor ranging from 0.01 to 0.75.

[0063] Methods of making a friction reducing coating include coating a surface of a component with a friction reducing coating by co-depositing an amorphous metal and a solid lubricant on the surface of the component. The friction reducing coating can be applied to a substrate using various techniques. For example, the friction reducing coating can be applied to a substrate by physical vapor deposition or thermal spraying (e.g., high velocity oxygen thermal spraying).

[0064] The surface can be textured using, for example, a laser or a lathe. The surface can be textured by using diamond cutting or engraving. The surface can also be textured by using a fine cutting tool with a periodic motion.

[0065] As discussed above, the friction reducing coating can be effective for reducing friction in, for example, bearings, gears, shafts, and the like.

[0066] Examples

[0067] The specific embodiments will be described with reference to the following examples. These examples are disclosed by way of illustration only and should not be used to limit the scope of the disclosure in any way.

[0068] Example One: Friction and wear reduction with a coating of amorphous metal and solid lubricant.

[0069] The disc is coated with a coating comprising an amorphous metal and a solid lubricant. The amorphous metal has 30 wt% iron, about 25 wt% chromium, about 20 wt% molybdenum, about 10 wt% tungsten, about 5 wt% boron, about 5 wt% manganese, about 3 wt% carbon, and about 2 wt% silicon of the total weight of the amorphous metal. The solid lubricant is tungsten disulfide, and the coating is 15 wt% of the solid lubricant of the total weight of the coating. The amorphous metal and the solid lubricant are mixed in a weight ratio of 80:15 to obtain a mixed powder. The mixed powder is then sprayed using a thermal spray process.

[0070] Figure 12A Friction reduction data for discs coated with friction reducing coatings according to embodiments of the present disclosure are shown. Figure 12A Friction values for dry uncoated steel discs, uncoated steel discs using a fluid lubricant, dry steel discs coated with a coating comprising an amorphous metal and a solid lubricant, and steel discs coated with a coating comprising an amorphous metal and a solid lubricant and a fluid lubricant are shown. Figure 12A It is shown that the coefficient of friction for steel discs coated with a coating comprising an amorphous metal and a solid lubricant is significantly reduced compared to the uncoated control.

[0071] Figure 12B Wear reduction data for discs coated with friction reducing coatings according to embodiments of the present disclosure are shown. Figure 12B Wear values between dry uncoated steel discs, uncoated steel discs using a fluid lubricant, steel discs coated with a fluid lubricant, uncoated steel discs, and dry steel discs coated with a coating comprising an amorphous metal and a solid lubricant, and steel discs coated with a coating comprising an amorphous metal and a solid lubricant and a fluid lubricant are shown. Figure 12B It is shown that the wear values for steel discs coated with a coating comprising an amorphous metal and a solid lubricant are significantly reduced compared to the uncoated control.

[0072] Example Two: Texturing to reduce friction.

[0073] Figure 13 Friction reduction of a textured surface compared to a smooth surface is shown. Line 13A depicts the friction generated by sliding a ceramic ball with a surface roughness of 0.147 microns against a smooth steel disc with a surface roughness of 0.05 microns in the presence of a fluid lubricant.

[0074] Line 13B depicts the friction generated by sliding a ceramic ball with a surface roughness of 0.147 microns against a textured steel disc with a surface roughness of 0.1736 microns in the presence of a fluid lubricant.

[0075] The coefficient of friction for the textured surface (13B) is unexpectedly lower than the smoother surface (13A).

[0076] The results of these examples show that friction unexpectedly decreases when a surface is coated with an amorphous metal and a solid lubricant and / or when a surface is textured.

[0077] Further aspects of the present disclosure are provided by the subject matter of the following clauses.

[0078] A coating that reduces friction, the coating comprising: an amorphous metal; and a solid lubricant, wherein the solid lubricant is dispersed throughout the coating with the amorphous metal or the solid lubricant is a layer on top of the amorphous metal.

[0079] The coating of the preceding clause, such that the amorphous metal is an iron-based alloy.

[0080] The coating of any of the preceding clauses, such that the amorphous metal comprises at least one of iron, chromium, molybdenum, cobalt, nickel, tungsten, boron, manganese, carbon, or silicon.

[0081] The coating of any of the preceding clauses, such that the solid lubricant comprises tungsten disulfide, tantalum disulfide, hexagonal boron nitride, molybdenum disulfide, graphite, tungsten oxide, boron oxide, nickel oxide, talc, polytetrafluoroethylene, or combinations thereof.

[0082] The coating of any of the preceding clauses, such that the coating has a surface roughness greater than 0.05 microns and less than 2 microns.

[0083] The coating of any of the preceding clauses, such that the coating has a surface roughness greater than 0.05 microns and less than 0.5 microns.

[0084] The coating of any of the preceding clauses, such that the coating has an amount of the solid lubricant ranging from 1 wt% to 30 wt% of the total weight of the coating.

[0085] A textured component comprising a coating according to any of the preceding clauses coated on a substrate and a contact surface positioned to contact the coating, wherein the coating is a textured surface in contact with an oil film, the textured component having a texture factor ranging from 0.01 to 0.75, the texture factor defined by (A1 / A2)*(Ra1 / Ra2)*thickness, A1 is the area of the textured surface, A2 is the area of the contact surface, Ra1 is the surface roughness of the textured surface, Ra2 is the surface roughness of the contact surface, and the thickness is the thickness of the oil film.

[0086] A textured component comprising a textured surface in contact with an oil film and a coating according to any of the preceding clauses coated on a substrate having a contact surface positioned to contact the textured surface, wherein the textured component has a texture factor in the range of 0.01 to 0.75, the texture factor being defined by (A1 / A2)*(Ra1 / Ra2)*thickness, A1 is the area of the textured surface, A2 is the area of the contact surface, Ra1 is the surface roughness of the textured surface, Ra2 is the surface roughness of the contact surface, and the thickness is the thickness of the oil film.

[0087] A coated component comprising a coating according to any of the preceding clauses coated on a substrate.

[0088] A coated component according to any of the preceding clauses, such that the substrate is a ferrous-based alloy.

[0089] A coated component according to any of the preceding clauses, such that the coated component is free of a fluid lubricant.

[0090] A coated component according to any of the preceding clauses, such that the coated component is a bearing component, a gear, or a spline shaft.

[0091] A coated component according to any of the preceding clauses, such that the coated component is a bearing having a raceway, the coating being applied to a surface of the raceway.

[0092] A coated component according to any of the preceding clauses, such that the coated component is a seal comprising a rotor having a rotor surface and a stator having a stator surface in contact with the rotor surface, wherein the coating is applied to the rotor surface, the stator surface, or both.

[0093] A coated component according to any of the preceding clauses, such that the coated component is a roller bearing having a roller, the substrate being at least a portion of the roller.

[0094] A coated component according to any of the preceding clauses, such that the substrate is an end portion of the roller of a roller bearing or a shoulder portion of the roller.

[0095] A coated component according to any of the preceding clauses, such that the roller is one of a ball, a cylindrical roller, a tapered roller, or a needle roller.

[0096] A gas turbine engine comprising a coated component according to any of the preceding clauses, such that the substrate is part of one or more of a fan bearing, a shaft, a pitch bearing, a bushing, or a gear box.

[0097] An aircraft comprising a coated component according to any of the preceding clauses, such that the substrate is part of one or more of a fan bearing, a shaft, a pitch bearing, or a gearbox.

[0098] A method of coating a component, the method comprising coating a surface of the component with a coating according to any of the preceding clauses by co-depositing an amorphous metal and a solid lubricant on the surface of the component; or depositing the amorphous metal and then depositing the solid lubricant on top of the amorphous metal.

[0099] A friction-reducing coating, the coating comprising an amorphous metal and a solid lubricant.

[0100] A coating according to the preceding clause, such that the solid lubricant is dispersed throughout the coating along with the amorphous metal.

[0101] A coating according to any of the preceding clauses, such that the amorphous metal is an iron-based alloy.

[0102] A coating according to any of the preceding clauses, such that the amorphous metal comprises at least one of iron, chromium, molybdenum, tungsten, boron, manganese, carbon, or silicon.

[0103] A coating according to any of the preceding clauses, such that the amorphous metal is an iron-based alloy comprising at least two of chromium, molybdenum, tungsten, boron, manganese, carbon, or silicon.

[0104] A coating according to any of the preceding clauses, such that the amorphous metal is an iron-based alloy comprising at least three of chromium, molybdenum, tungsten, boron, manganese, carbon, or silicon.

[0105] A coating according to any of the preceding clauses, such that the solid lubricant comprises tungsten disulfide, tantalum disulfide, hexagonal boron nitride, molybdenum disulfide, graphite, tungsten oxide, boron oxide, nickel oxide, talc, polytetrafluoroethylene, or combinations thereof.

[0106] A coating according to any of the preceding clauses, such that the coating has a surface roughness greater than 0.05 microns and less than 2 microns.

[0107] A coating according to any of the preceding clauses, such that the coating has a surface roughness greater than 0.05 microns and less than 0.5 microns.

[0108] A coating according to any of the preceding clauses, such that the coating has an amount of the solid lubricant in a range of 1% to 30% by weight of the total weight of the coating.

[0109] A textured component comprising a coating according to any of the preceding clauses coated on a substrate and a contact surface positioned to contact the coating such that the coating is a textured surface, the textured component having a texture factor in the range 0.01 to 0.75, the texture factor being defined by (A1 / A2)*(Ra1 / Ra2)*thickness, A1 being the area of the textured surface, A2 being the area of the contact surface, Ra1 being the surface roughness of the textured surface, Ra2 being the surface roughness of the contact surface and the thickness being the thickness of the textured surface.

[0110] A textured component comprising a textured surface and a coating according to any of the preceding clauses coated on a substrate, the substrate having a contact surface positioned to contact the textured surface, wherein the textured component has a texture factor in the range 0.01 to 0.75, the texture factor being defined by (A1 / A2)*(Ra1 / Ra2)*thickness, A1 being the area of the textured surface, A2 being the area of the contact surface, Ra1 being the surface roughness of the textured surface, Ra2 being the surface roughness of the contact surface and the thickness being the thickness of the textured surface.

[0111] A coated component comprising a coating according to any of the preceding clauses coated on a substrate.

[0112] A coated component according to the preceding clause such that the substrate is a ferrous based alloy.

[0113] A coated component according to the preceding clause such that the substrate is a bearing component, a gear or a spline shaft.

[0114] A coated component according to the preceding clause such that the substrate is a bearing raceway, an squeeze film damper, a ball of a ball bearing, a conical roller of a roller bearing, a cylindrical roller of a roller bearing, a journal bearing component or a needle roller of a roller bearing.

[0115] A coated component according to the preceding clause such that the substrate is an end of a roller of a roller bearing or a shoulder of a roller of a roller bearing.

[0116] A coated component according to any of the preceding clauses such that the coated component is a bearing component, a gear or a spline shaft.

[0117] A coated component according to any of the preceding clauses such that the coated component is a bearing having a raceway, the coating being applied to a surface of the raceway.

[0118] A coated component according to any of the preceding clauses such that the coated component is a roller bearing having a roller, the substrate being at least a portion of the roller.

[0119] The coated component of any of the preceding clauses, such that the substrate is an end of the roller of a roller bearing or a shoulder of the roller.

[0120] The coated component of any of the preceding clauses, such that the roller is one of a ball, a cylindrical roller, a tapered roller, or a needle roller.

[0121] The coated component of any of the preceding clauses, such that the coated component is a seal comprising a rotor having a rotor surface and a stator having a stator surface in contact with the rotor surface, wherein the coating is applied to the rotor surface, the stator surface, or both.

[0122] A gas turbine engine comprising the coated component of any of the preceding clauses, such that the substrate is part of one or more of a fan bearing, a shaft, a pitch bearing, or a gear box.

[0123] An aircraft comprising the coated component of any of the preceding clauses, such that the substrate is part of one or more of a fan bearing, a shaft, a pitch bearing, or a gear box.

[0124] A method of coating a component, the method comprising coating a surface of the component with the coating of any of the preceding clauses by co-depositing an amorphous metal and a solid lubricant on the surface of the component.

[0125] A textured component comprising a textured surface having an area A1, a thickness, a surface roughness Ra1, and a contact surface having an area A2 and a surface roughness Ra2, such that the component has a texturing factor defined by (A1 / A2)*(Ra1 / Ra2)*thickness, and the texturing factor ranges from 0.01 to 0.75.

[0126] The textured component of the preceding clause, such that the area ratio A1 / A2 ranges from 0.2 to 0.3.

[0127] The textured component of any of the preceding clauses, such that Ra1 ranges from 0.1 microns to 5 microns.

[0128] The textured component of any of the preceding clauses, such that Ra2 ranges from 0.1 microns to 0.3 microns.

[0129] The textured component of any of the preceding clauses, such that the contact surface is untextured.

[0130] The textured component of any of the preceding clauses, such that the thickness of the textured surface ranges from 0.05 millimeters to 0.2 millimeters.

[0131] The textured component of any of the preceding clauses, such that the textured surface is a friction-reducing coating of any of the preceding clauses.

[0132] The textured component of any of the preceding clauses, such that the contact surface is a friction-reducing coating of any of the preceding clauses.

[0133] The textured component of any of the preceding clauses, such that the textured surface is on a substrate.

[0134] The textured component of any of the preceding clauses, such that the substrate is an iron-based alloy.

[0135] The textured component of any of the preceding clauses, such that the textured component is free of a fluid lubricant.

[0136] The textured component of the preceding clause, such that the substrate is a bearing component, a gear, or a spline shaft.

[0137] The textured component of the preceding clause, such that the substrate is a bearing raceway, an squeeze film damper, a ball of a ball bearing, a conical roller of a roller bearing, a cylindrical roller of a roller bearing, a journal bearing component, or a needle roller of a roller bearing.

[0138] The textured component of any of the preceding clauses, such that the substrate is an end of a roller of a roller bearing or a shoulder of a roller of a roller bearing.

[0139] A gas turbine engine comprising the textured component of any of the preceding clauses, such that the substrate is part of one or more of a fan bearing, a shaft, a pitch bearing, or a gear box.

[0140] An aircraft comprising the textured component of any of the preceding clauses, such that the substrate is part of one or more of a fan bearing, a shaft, a pitch bearing, or a gear box.

[0141] While the foregoing description has been directed to some exemplary embodiments of the present disclosure, other variations and modifications will be apparent to those skilled in the art and can be made without departing from the disclosure. Furthermore, features described in conjunction with one embodiment can be used in conjunction with other embodiments, even if such features are not explicitly stated in such combinations.

Claims

1. A coating for reducing friction, characterized in that, The coating comprises: Amorphous metals; and solid lubricants The solid lubricant is dispersed throughout the coating along with the amorphous metal, or the solid lubricant is a layer on top of the amorphous metal.

2. The coating according to claim 1, characterized in that, The amorphous metal mentioned therein is an iron-based alloy.

3. The coating according to claim 1, characterized in that, The amorphous metal mentioned above includes at least one of iron, chromium, molybdenum, cobalt, nickel, tungsten, boron, manganese, carbon, or silicon.

4. The coating according to claim 1, characterized in that, The solid lubricant mentioned therein includes tungsten disulfide, tantalum disulfide, hexagonal boron nitride, molybdenum disulfide, graphite, tungsten oxide, boron oxide, nickel oxide, talc, polytetrafluoroethylene, or combinations thereof.

5. The coating according to claim 1, characterized in that, The coating has a surface roughness greater than 0.05 micrometers and less than 2 micrometers.

6. The coating according to claim 1, characterized in that, The coating has a surface roughness greater than 0.05 micrometers and less than 0.5 micrometers.

7. The coating according to claim 1, characterized in that, The coating has an amount of solid lubricant ranging from 1% to 30% by weight of the total weight of the coating.

8. A textured component, characterized in that, The coating includes a coating according to claim 1 applied to a substrate and a contact surface positioned to contact the coating, wherein the coating is a textured surface in contact with an oil film, the textured component having a texture factor ranging from 0.01 to 0.75, the texture factor being defined by (A1 / A2)*(Ra1 / Ra2)*thickness, where A1 is the area of ​​the textured surface, A2 is the area of ​​the contact surface, Ra1 is the surface roughness of the textured surface, Ra2 is the surface roughness of the contact surface, and the thickness is the thickness of the oil film.

9. A textured component, characterized in that, The coating comprises a textured surface in contact with an oil film and a coating applied to a substrate according to claim 1, wherein the substrate has a contact surface positioned to contact the textured surface, wherein the textured component has a texture factor ranging from 0.01 to 0.75, the texture factor being defined by (A1 / A2)*(Ra1 / Ra2)*thickness, where A1 is the area of ​​the textured surface, A2 is the area of ​​the contact surface, Ra1 is the surface roughness of the textured surface, Ra2 is the surface roughness of the contact surface, and the thickness is the thickness of the oil film.

10. A coated component, characterized in that, This includes a coating applied to a substrate, as described in claim 1.

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