Laminated Copper Alloy Coating With Non-Spherical Hard Particles
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Solution Overview
Problem
The existing methods for forming hard coatings have insufficient formation efficiency, which limits the effectiveness of the coating layer in terms of adhesion and durability.
Innovation Solution
A method involving the spraying of a mixture containing precipitation hardening copper alloy particles and hard particles with non-spherical shapes onto a base substrate, where the hard particles have a median aspect ratio of 1.2 or more and are harder than the copper alloy particles, to form a coating layer with high formation efficiency and improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal powder is sprayed at high speed to cause deformation-induced transformation, then the coating hardness is improved, but the formation efficiency of the coating is insufficient
Solution Approach 1:
The invention changes the particle shape parameter from spherical to non-spherical (aspect ratio ≥1.2) and uses precipitation hardening copper alloy with specific composition ranges. These parameter changes enable the coating to achieve both high hardness (500-1500 HV) and high formation efficiency (≥80%) by allowing lower spraying velocities while maintaining deformation-induced transformation effects
Solution Approach 2:
The invention uses composite material composition by combining precipitation hardening copper alloy particles (containing Cu, Ni, Si, Cr, Zn) with specific weight ratios (Cu: 70-95%, Ni: 3-20%, Si: 0.1-5%). This composite structure provides both the ductility needed for deformation-induced transformation and the hardness required for the coating, resolving the contradiction between hardness and formation efficiency
2Reliability
If non-spherical hard particles with aspect ratio ≥1.2 are used, then adhesion and formation efficiency are improved, but the device complexity increases
Solution Approach 1:
The invention uses gas atomization or water atomization methods to produce non-spherical particles with controlled aspect ratios. These pneumatic/hydraulic processes create the desired particle morphology during atomization without requiring complex post-processing, thereby improving adhesion and formation efficiency while limiting device complexity increase
Solution Approach 2:
The invention specifies precise parameter ranges for particle production (aspect ratio 1.2-2.0, particle size 10-50 μm, specific composition ranges) that optimize both adhesion performance and manufacturing feasibility. By controlling parameters within these ranges, the invention achieves reliable adhesion without excessive complexity in particle preparation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves a coating layer with high formation efficiency, enhanced abrasion resistance, and improved heat conductivity, with the non-spherical hard particles providing an anchor effect and increased specific surface area for better adhesion and durability.
Implementation Method 1
forming a hard coating on the surface of a base substrate through deformation-induced transformation in a cold state
Implementation Method 2
spraying a mixture in a non-molten state including precipitation hardening copper alloy particles
Implementation Method 3
The coated film is formed by causing a powder mixture including a powder of a sliding alloy and hard particles to collide against a substrate by a high-speed gas stream
Implementation Method 4
the non-spherical hard particles providing an anchor effect and increased specific surface area for better adhesion and durability
Data Source
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AI summary
A method for producing a laminated member includes a step of spraying a mixture in a non-molten state including a plurality of precipitation hardening copper alloy particles and a plurality of hard particles that have non-spherical shapes having a median aspect ratio of equal to or more than 1.2 and are harder than the copper alloy particles onto a base substrate to form a coating layer on the base substrate.