Aluminum Bronze Sintered Bearing With Surface Pore Control
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Solution Overview
Problem
Existing sintered bearings, such as Cu—Ni—Sn—C—P-based and aluminum bronze-based bearings, face challenges in achieving sufficient corrosion resistance, mechanical strength, abrasion resistance, compactness, and cost-effectiveness, particularly when exposed to inferior quality gasoline containing organic acids, which degrades their performance and lifespan.
Innovation Solution
A sintered bearing composed of 3 to 12% aluminum, 0.05 to 0.5% phosphorus, and the balance copper, with added sintering aids like silicon, tin, and fluoride, which enhances corrosion resistance, mechanical characteristics, and compactness through controlled sintering and pore structure optimization, suitable for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a copper-based sintered bearing is used to improve mechanical strength, then strength is enhanced, but corrosion resistance deteriorates when exposed to organic acids in inferior gasoline
Solution Approach 1:
The invention changes the chemical composition parameters by specifying aluminum content at 3-12% and phosphorus content at 0.05-0.5%, creating an aluminum bronze-based material that fundamentally alters both strength and corrosion resistance properties compared to conventional copper-based bearings
Solution Approach 2:
The invention creates a composite material system combining aluminum, phosphorus, and copper with sintering aids, where the interaction between these elements produces a material with superior combined properties of strength and corrosion resistance that neither component achieves alone
2Strength
If Ni is added to enhance strength and abrasion resistance, then mechanical characteristics are improved, but cost increases due to Ni being a rare metal
Solution Approach 1:
The invention replaces expensive rare metals like Ni with more abundant and cheaper elements (aluminum and phosphorus) that can achieve similar or superior performance, significantly reducing material cost while maintaining mechanical characteristics
Solution Approach 2:
The invention changes the compositional parameters from Ni-containing alloys to aluminum-phosphorus-copper systems, achieving cost reduction through substitution with cheaper elements while maintaining or improving mechanical properties
3Reliability
If aluminum-containing copper alloy powder is used to improve corrosion resistance, then corrosion resistance is enhanced, but sintering is inhibited by aluminum oxide formation
Solution Approach 1:
The invention introduces sintering aids as intermediary substances that facilitate the sintering process by counteracting the harmful effects of aluminum oxide, enabling successful sintering of aluminum-containing alloys that would otherwise be difficult to process
Solution Approach 2:
The invention converts the harmful aluminum oxide layer that inhibits sintering into a beneficial protective layer that enhances corrosion resistance, using sintering aids to control oxide formation and distribution during the sintering process
4Weight of moving object
If the bearing is miniaturized to reduce fuel pump weight and size, then compactness is achieved, but abrasion resistance and strength requirements become more stringent
Solution Approach 1:
The invention changes the material composition parameters to optimize the strength-to-weight ratio, using aluminum bronze with specific aluminum and phosphorus content ranges that provide superior specific strength and abrasion resistance for miniaturized applications
Solution Approach 2:
The invention creates a composite material structure with optimized pore distribution and phase composition that enhances abrasion resistance and strength while maintaining compact size, allowing the bearing to withstand higher stresses in miniaturized fuel pumps
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 solution provides enhanced corrosion resistance, mechanical strength, abrasion resistance, and cost-effectiveness, ensuring the sintered bearing's performance and durability, particularly in environments with inferior gasoline, while being suitable for mass production and use in fuel pumps.
Implementation Method 1
a sintered bearing, comprising 3 to 12% by mass of aluminum, 0.05 to 0.5% by mass of phosphorus, and the balance comprising copper as a main component, and inevitable impurities, the sintered bearing having a structure in which an aluminum-copper alloy is sintered
Implementation Method 2
aluminum oxide covering the surface of aluminum-containing copper alloy powder to be generated during sintering
Data Source
AI summary
Provided is a sintered bearing (1), including 3 to 12% by mass of aluminum, 0.05 to 0.5% by mass of phosphorus, and the balance including copper as a main component, and inevitable impurities, the sintered bearing (1) having a structure in which an aluminum-copper alloy is sintered with a sintering aid added to raw material powder, a pore (db, do) in a surface layer portion of the sintered bearing (1) being formed smaller than an internal pore (di).