Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C1/00—Making non-ferrous alloys
  • C22C1/04—Making non-ferrous alloys by powder metallurgy
  • C22C1/0408—Light metal alloys
  • C22C1/0416—Aluminium-based alloys
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/10—Sintering only
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
  • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
  • C23C4/06—Metallic material
  • C23C4/067—Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
  • F16C33/02—Parts of sliding-contact bearings
  • F16C33/04—Brasses; Bushes; Linings
  • F16C33/06—Sliding surface mainly made of metal
  • F16C33/12—Structural composition; Use of special materials or surface treatments, e.g. for rust-proofing
  • F16C33/121—Use of special materials
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
  • F16C33/02—Parts of sliding-contact bearings
  • F16C33/04—Brasses; Bushes; Linings
  • F16C33/06—Sliding surface mainly made of metal
  • F16C33/14—Special methods of manufacture; Running-in
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C2223/00—Surface treatments; Hardening; Coating
  • F16C2223/02—Mechanical treatment, e.g. finishing
  • F16C2223/08—Mechanical treatment, e.g. finishing shot-peening, blasting
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C2223/00—Surface treatments; Hardening; Coating
  • F16C2223/30—Coating surfaces
  • F16C2223/32—Coating surfaces by attaching pre-existing layers, e.g. resin sheets or foils by adhesion to a substrate; Laminating
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C2223/00—Surface treatments; Hardening; Coating
  • F16C2223/30—Coating surfaces
  • F16C2223/42—Coating surfaces by spraying the coating material, e.g. plasma spraying
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49636—Process for making bearing or component thereof
  • Y10T29/49643—Rotary bearing
  • Y10T29/49647—Plain bearing
  • Y10T29/49668—Sleeve or bushing making
  • Y10T29/49671—Strip or blank material shaping
  • Y10T29/49673—Die-press shaping
  • Y10T29/49675—Die-press shaping having inner lining layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
  • Y10T29/49988—Metal casting
  • Y10T29/49991—Combined with rolling

Definitions

• An aluminium-lead bearing alloy optionally containing tin, silicon, copper and cadmium, is produced in strip form by spraying droplets of the molten metal onto a substrate under conditions such that they strike the substrate in a highly undercooled condition and are chilled to solidification at the substrate at the rate of at least 103C/second so as to precipitate the lead in the form of a fine dispersion of separate particles.
• the deposit of solidified droplets is then subjected to compaction.
• a surface layer of commercial purity aluminium or other suitable aluminium alloy may be applied to one or both surfaces of the aluminium-lead alloy strip to facilitate the production of a composite bearing alloysteel strip by a roll-bonding procedure.
• the present invention relates to the production of bearing alloys in strip form, either united to a backing strip of steel or other suitable metal in strip form or in the form of a self-supporting strip for bonding to a backing strip in a subsequent operation.
• the lead constituent Under conventional casting procedures there is a tendency for the lead constituent to be unevenly distributed as a result .of the difference in density of lead and aluminium and for the lead to form a continuous interdendritic network. This continuous network severely weakens the material, reducing tensile strength and fatigue resistance. Some improvement may be effected by working or heating to break up the structure.
• the precipitation of the lead alloying constituent in the form of nonconnected particles uniformly distributed through the aluminium matrix could lead to a significant improvement in the strength and fatigue resistance of the alloy. It is well understood that the particle size of a precipitated alloying constituent is very largely controlled by the rate at which the molten metal is cooled during the casting process. Although rapid quenching is conventionally employed in the known method of producing bearing alloys in shapes suitable for bearing application nevertheless these have not permitted the production of aluminium-lead bearing alloys with a uniform distribution of finely divided lead particles.
• a process has been described by A.R.E. Singer in Metals and Materials, June 1970, pages 246-257, for forming metal strip by entraining fine droplets of molten metal in a stream of gas, preferably nitrogen, and projecting the entrained droplets against a moving substrate to form a somewhat porous, but coherent strip, which is then compacted by a hot rolling operation, i.e., rolling at a temperature in the range of 200 to 500C.
• the droplets arecooled by their contact with the gas, so that, in dependence upon the distance between the metal spray nozzle and the target substrate, amongst other factors, the droplets undergo a substantial degree of cooling before striking the target. Under correctly selected conditions the metal strikes the target substrate in the form of undercooled droplets which flatten and almost instantaneously solidify under the high rate of chilling at the target surface.
• an aluminium alloy containing l-l% Pb (and optionally other alloying constituents), is produced in strip form by employment of the abovementioned spray casting technique, followed by rolling, without or after separation from the substrate on which it has been deposited.
• spray casting technique followed by rolling, without or after separation from the substrate on which it has been deposited.
• the alloy may contain up to 30 percent, but preferably only up to 5% Sn, up to 12% Si and/or up to about 5% Cd, as is already known for bearing alloys. It may also contain up to about 2% Cu to provide greater strength. However these other additions have little or no effect on the distribution of lead particles in the flattened, solidified droplets of bearing metal deposited on the substrate.
• a backing strip of steel (or other material suitable for the purpose) is prepared, preferably by shotor grit-blasting, to bond with the spray-cast metal deposited on it.
• a thin layer of commercial purity aluminium or other suitable intermediate aluminium alloy is first deposited on the backing strip beforethe layer of bearing alloy is deposited.
• it is preferred to make a two-layer stock material which can then be bonded to a suitable steel backing in a subsequent rolling operation. In this way it may be necessary to prepare the surface of the substrate so as to avoid permanent adhesion of the spraycast metal.
• the adhesion of the bearing alloy is low, this is preferably applied first to the substrate, followed by the layer of commercial purity aluminium (or other material) for forming the intermediate layer of the final bearing. After casting the composite is stripped from the substrate and compacted by rolling.
• the compaction of the spray-cast material is preferably achieved by preceding the hot roll consolidation by cold rolling (between 20-50 percent reduction). It should be added that the hot roll consolidation is still required to break down the droplet boundary films so as to permit inter-droplet welding.
• the stock material is prepared in the form of a three-ply'sandwich consisting of the bearing alloy coated on both faces by a thin layer of commercial purity aluminium.
• the commercial purity aluminium may be replaced by any other alloy which will become firmly bonded to the bearing alloy during the course of the process and to a steel backing either in the course of deposition or in a subsequent roll-bonding operation.
• the function of the commercial purity aluminium layers are two-fold. First, they greatly assist the hot roll consolidation to be carried out to produce a three-ply alloy. Second, one layer permits maximum adhesion of the alloy to the steel backing strip during subsequent There are added advantages with this procedure. There would be no need to identify the faces of the three-ply strip prior to roll bonding to indicate which side has the commercial purity aluminium, as would be the case with a two-ply system. Also, the amounts of expensive lead (or other alloying constituent) wasted in swarf obtained from the final machining operation would be negligible.
• the layer of aluminium-lead bearing alloy is deposited under conditions such that, on meeting the substrate, the rate of cooling of the droplets is at least C/sec. Preferably the rate is about 10 C/sec. or even higher.
• the droplet size is brought to below 1 mm by the spraying conditions and more preferably the metal is sprayed under such conditions that the droplet size is in the range of 0.1 to 0.2 mm.
• the choice of substrate must be compatible with the requirements of the bearing backing plate and with the process requirement that it must be capable of further rolling.
• Annealed mild steel sheet of thickness 0.72 mm (0.028 in.) which was prepared by grit-blasting with chill-cast angular grit to produce a roughened surface, has been used. It is desirable to minimise surface oxidation by avoiding unnecessary delay between this surface preparation and the spray deposition of the intermediate layer (or underlay), followed by the spray deposition of the bearing alloy itself.
• the choice of the alloy for the underlay is governed by the requirement of obtaining maximum adherence of the final overlay and either commercial purity aluminium or an Al-Si alloy (up to the eutectic composition 12% Si) is suitable.
• the spraying conditions are less critical for the underlay than for the overlay of bearing alloy which in one example was an alloy containing 6% Pb, 4% Si, 1.1% Cd, 0.1% Cu, 0.1% Mg and remainder Al.
• the alloy was sprayed from a temperature of 850C with a nozzle to substrate distance of 350 mm (14 in.). Nitrogen was used as the spraying gas with a measured consumption of 1,120 litres/1 kg (18 cu.ft./l lb.) of metal.
• the thicknesses of the underlay and overlay deposit can be arranged to suit the requirements of the final rolled bearing laminate. In the present case, it was arranged that the final total thickness of both layers after rolling was 0.56 mm (0.022 in.) of which 0.13 mm (0.005 in.) is the intermediate underlay of 99.7 percent aluminium. These thicknesses are those after rolling which is carried out in the temperature range 300-450C using the minimum preheat necessary prior to rolling.
• the rolling reduction used is that required to break up the deposit structure and to heal porosity and this should not be less than 60 percent reduction of deposit.
• the effect of hot rolling on the structure is to cause further precipitation of the second phase and growth of existing second phase particles but nevertheless it remains a structure in which the finelydistributed and non-connnecting particles of second phases can have an average size 1 pm.
• the bearing stock material thus formed, may be united with aluminised steel strip by roll bonding in conventional manner.
• the process of the present invention may also be employed for the production of Al-Sn bearing alloys in separate strip form or united to a steel backing.
• a method of producing aluminium alloy material for the production of bearings comprising the formation of strip material by spraying molten aluminium alloy containing ll0% Pb onto a moving substrate and subsequently compacting the strip of spray-deposited metal, the sprayed metal being entrained in a stream of inert gas under such conditions that the droplets are substantially undercooled before striking the substrate, the cooling rate to completion of solidification after contact with the substrate for the majority of the droplets being at a rate of at least 10 C/sec.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• General Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Manufacturing & Machinery (AREA)
• Physics & Mathematics (AREA)
• Plasma & Fusion (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Coating By Spraying Or Casting (AREA)
• Sliding-Contact Bearings (AREA)
• Metal Rolling (AREA)

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Cited By (6)

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Citations (3)

• 1973
  • 1973-06-14 US US00369804A patent/US3833983A/en not_active Expired - Lifetime
  • 1973-06-20 DE DE2331498A patent/DE2331498A1/de active Pending
  • 1973-06-20 CA CA174,493A patent/CA1024833A/en not_active Expired
  • 1973-06-20 IT IT7325687A patent/IT992579B/it active
  • 1973-06-21 FR FR7322646A patent/FR2189527B3/fr not_active Expired

Patent Citations (3)

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