Copper Alloy Sliding Coating for Wear-Resistant Engine Members
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Solution Overview
Problem
Conventional methods for enhancing wear resistance of aluminum-based sliding members, such as using metal particles, fail to form a strong coating layer when hard particles are used, resulting in weak chemical bonds and insufficient wear resistance.
Innovation Solution
A coating layer is formed using a combination of two or more kinds of precipitation hardened copper alloy particles with different compositions, which are plastically deformed and chemically bonded to each other, creating a high-strength aggregate with improved wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hard particles such as tungsten carbide or silicon nitride are added to improve wear resistance, then wear resistance is enhanced, but the coating layer strength deteriorates because hard particles only embed into soft particles providing weak chemical bonds
Solution Approach 1:
The patent uses a composite coating layer containing both soft copper alloy particles and hard tungsten carbide particles. The soft copper alloy particles form a strong bonding matrix through plastic deformation and chemical bonding, while the hard tungsten carbide particles provide wear resistance. This composite structure resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The soft copper alloy particles act as an intermediary between the hard tungsten carbide particles and the base material. They form strong chemical bonds with both the base material and the hard particles, providing a strong bonding matrix that prevents the coating layer from becoming weak despite the presence of hard particles.
2Strength
If soft metal particles are used to form a coating layer through plastic deformation, then coating layer strength is achieved, but wear resistance deteriorates due to insufficient hardness
Solution Approach 1:
The patent creates a composite coating layer that combines soft copper alloy particles (providing strength through plastic deformation and chemical bonding) with hard tungsten carbide particles (providing wear resistance). This composite approach allows the coating to simultaneously achieve both strength and wear resistance.
Solution Approach 2:
Different regions of the coating layer have different properties: the copper alloy particles provide softness and bonding capability, while the tungsten carbide particles provide local hardness and wear resistance. This local differentiation of material properties allows the coating to satisfy both requirements simultaneously.
3Weight of moving object
If aluminum or aluminum alloy is used for light weight and high strength, then weight reduction is achieved, but wear resistance deteriorates due to low inherent wear resistance
Solution Approach 1:
The patent applies a composite coating layer on the aluminum or aluminum alloy base material. The coating contains both soft copper alloy particles for bonding and hard tungsten carbide particles for wear resistance, providing the aluminum base material with enhanced wear resistance while maintaining its light weight advantage.
Solution Approach 2:
The coating layer is applied in advance to the aluminum base material before the component enters service. This preliminary protective layer prevents the underlying aluminum from experiencing wear, allowing the component to maintain its light weight while gaining wear resistance from the coating.
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 use of a particle aggregate with precipitation hardened copper alloy particles provides a sliding member with superior wear resistance and corrosion resistance, suitable for internal combustion engine components.
Implementation Method 1
the precipitation hardened copper alloy particles are plastically deformed to be physically adhered to each other
Implementation Method 2
The sprayed particles are plastically deformed by kinetic energy and are adhered to the surface of the base material
Implementation Method 3
they form a reaction layer and are also chemically bonded to each other
Data Source
AI summary
A sliding member of the present invention includes a base material and a coating layer that is formed on the base material. The coating layer includes a particle aggregate, and the particle aggregate contains two or more kinds of precipitation hardened copper alloy particles that have different compositions. The sliding member has high coating strength and superior wear resistance.