Copper Alloy Laminate Coating for Abrasion-Resistant Sliding Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional hard coatings exhibit insufficient abrasion resistance.
Innovation Solution
A laminate with a coating layer comprising copper alloy portions derived from precipitation-hardening copper alloy particles and harder, non-spherical hard particle portions, where these portions are bounded via interfaces, enhancing adhesion and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard coating is formed on a base substrate 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 patent applies composite materials by combining two distinct types of particles (first particles and second particles) with different properties in the coating layer. The first particles provide hardness through deformation-induced transformation, while the second particles contribute to abrasion resistance. This composite structure resolves the contradiction by integrating materials with complementary functions, where neither material alone could achieve both high hardness and excellent abrasion resistance.
Solution Approach 2:
The patent implements local quality by creating distinct regions within the coating layer with different functional characteristics. The first particles undergo deformation-induced transformation to create hard regions, while the second particles form regions optimized for abrasion resistance. This spatial differentiation of material properties within the coating layer allows simultaneous achievement of local hardness and overall abrasion resistance.
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 substrate may be insufficient
Solution Approach 1:
The patent applies parameter changes by utilizing the kinetic energy parameters of the sprayed particles to induce deformation-induced transformation in the first particles. By controlling the spray velocity and impact conditions, the particles undergo phase transformation that enhances both hardness and adhesion. The parameter change from spherical to deformed morphology during impact improves mechanical interlocking with the substrate.
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 thermal conductivity, with improved adhesion between the base substrate and the coating layer due to the anchor effect and kinetic energy conversion during deposition.
Implementation Method 1
spraying metal powder in a solid state onto a surface of a base substrate along with compressed air as a medium, to form a hard metal coating. The metal powder is made of a metal material that can undergo deformation-induced transformation. The method involves spraying the metal powder onto the base substrate at such a high speed that causes deformation-induced transformation
Implementation Method 2
accumulate and layer the metal powder on the surface of the base substrate while plastically deforming the metal powder into a flat shape
Implementation Method 3
the coating layer includes copper alloy portions derived from precipitation-hardening copper alloy 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.