Sliding Member with Roughened Copper Layer for Heavy Load Bonding
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Solution Overview
Problem
Existing sliding members with metallic bases and copper-based sliding layers face challenges in achieving strong joining strength, especially under heavy loads, due to surface stains and insufficient diffusion between the metals, which can lead to inadequate bonding and reduced performance in applications like oil hydraulic pumps.
Innovation Solution
The surface of the metallic base is roughened using impact processing with metal powder to create an anchoring effect, allowing for improved bonding between the supporting and sliding layers through thermal spraying, and subsequent densification of the sliding layer via shot blasting to enhance hardness and roughness, resulting in a sliding member with a two-layer configuration suitable for heavy load applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermal spraying method is used to form sliding layer on metallic base, then sliding layer can be formed on flat or non-flat surfaces, but joining strength between supporting layer and sliding layer is insufficient under heavy loads
Solution Approach 1:
The surface of the metallic base is roughened by impact processing with metal powder before thermal spraying. This preliminary action creates an anchoring effect that significantly improves joining strength between the supporting layer and sliding layer, while maintaining the ability to form sliding layers on both flat and non-flat surfaces.
2Reliability
If cleaning process is performed to remove surface stains, then solid state diffusion between metals is enabled, but additional process steps and time are required
Solution Approach 1:
The harmful surface stains are removed through impact processing with metal powder, which extracts and eliminates contaminants from the metallic base surface. This creates a clean surface that enables solid state diffusion between the supporting layer and sliding layer, improving bonding reliability without requiring separate cleaning process steps.
3Ease of operation
If sliding layer is made with low mechanical strength copper-based alloy, then lubricating property is improved, but overall strength of sliding member is reduced
Solution Approach 1:
The sliding member is constructed as a composite material system with a metallic base (supporting layer) providing high mechanical strength and a copper-based alloy sliding layer providing lubricating properties. The roughened surface interface between layers ensures strong bonding, allowing the composite structure to simultaneously achieve both strength and ease of sliding operation.
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
This approach significantly enhances the joining strength and sliding properties of the sliding member, enabling it to withstand heavy loads while maintaining a suitable surface roughness and hardness, thus improving its performance in hydraulic equipment like oil hydraulic pumps.
Implementation Method 1
roughening the surface of the supporting layer by allowing metal powder to impact on the surface
Implementation Method 2
a sliding layer which is formed by attaching a second metallic material to the roughened surface of the supporting layer with thermal spraying
Implementation Method 3
The sliding surface is formed on a surface of the sliding layer which is subjected to shot blasting
Data Source
AI summary
A sliding member having a supporting layer composed of an iron-based metallic material and a sliding layer formed on a surface of the supporting layer and composed of a copper-based metallic material. The surface of the supporting layer and the sliding layer have non-flat surfaces. A sliding surface having a non-flat surface is formed on the surface of the sliding layer. The sliding layer is formed on the roughened surface of the supporting layer by thermal spraying. The surface of the sliding layer is then subjected to a shot blasting treatment to form the sliding surface which has an uneven surface having an arithmetic average roughness (Ra) of more than 0 μm and 2.0 μm or less, a ten-point average roughness (Rz) of more than 0 μm and 7.5 μm or less and a surface hardness (Hv) of 150-250, and which slidably supports an object to be slid.