Copper Alloy Laminate Coating With Non-Spherical Hard Particles
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Solution Overview
Problem
Conventional hard coatings are insufficient in abrasion resistance.
Innovation Solution
A laminate with a coating layer comprising copper alloy portions derived from precipitation-hardening copper alloy particles and hard particle portions, where the hard particle portions are harder than the copper alloy portions and have a non-spherical shape, bounded via interfaces, is formed on a base substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard coating is formed through deformation-induced transformation by spraying metal powder at high speed, then the metal coating becomes harder than the metal powder, but the abrasion resistance is insufficient
Solution Approach 1:
The invention uses a composite coating layer containing both copper alloy particles and hard particles (such as ceramic particles). The copper alloy particles provide ductility and bonding, while the hard particles provide abrasion resistance. This composite structure resolves the contradiction by combining materials with complementary properties rather than relying solely on deformation-induced hardening of metal powder.
Solution Approach 2:
The coating layer is designed with local quality differentiation where hard particles are distributed within the copper alloy matrix. The hard particles are strategically positioned to provide localized abrasion resistance where needed, while the copper alloy portions provide overall structural integrity and bonding to the base substrate.
2Strength
If metal powder is sprayed at high speed to cause deformation-induced transformation, then the coating becomes harder, but the adhesion between coating and base substrate may be insufficient
Solution Approach 1:
The invention changes the parameters of the coating particles by using pre-formed composite particles containing both copper alloy and hard particles, rather than spraying simple metal powder. The particles are designed with specific size distributions and compositional ratios to optimize both adhesion and hardness. The copper alloy content and particle morphology are controlled to ensure proper bonding to the base substrate while maintaining coating hardness.
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 laminate achieves excellent abrasion resistance, high tensile strength, and high thermal conductivity, with improved adhesion between the base substrate and the coating layer due to the anchor effect and deposition processes.
Implementation Method 1
a coating layer formed on the base substrate, the coating layer including copper alloy portions derived from precipitation-hardening copper alloy particles
Implementation Method 2
hard particle portions which are harder than the copper alloy portions, each of the hard particle portions being derived from hard particles
Data Source
AI summary
A laminate includes a base substrate, and a coating layer formed on the base substrate. The coating layer includes a copper alloy portions derived from precipitation-hardening copper alloy particles and hard particle portions which are harder than the copper alloy portions, the hard particle portions are derived from hard particles, and the parts bond with each other via an interface. Each of the hard particle portions has a non-spherical shape.A sliding member includes the laminate in at least one sliding portion.A method for manufacturing a laminate includes a step of spraying a mixture in a non-molten state including precipitation-hardening copper alloy particles and hard particles having a non-spherical shape and being harder than the copper alloy particles onto a base substrate, to form a coating layer on the base substrate.