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**The Application of Thermal Spraying Skills in the Production of Sliding Bearings**
With the rapid development of modern science and technology, there has been an increasing demand for advanced functional performance in military equipment, industrial machinery, scientific instruments, and more. As a result, the components used in these systems must meet stricter requirements. Traditional methods such as casting, forging, and welding often become inefficient or economically unviable when trying to achieve special properties. To address this, some functional coatings are applied to the surface of conventional materials, creating a tailored working surface that enhances performance while saving resources.
Thermal spraying is a technique where a heat source is used to melt or partially melt the coating material, which is then sprayed onto a pre-treated substrate at high speed. This process forms a thin layer of fine particles that imparts specific functions to the surface of the base material. It plays a crucial role in surface engineering. Different coating materials and processes can be used to create wear-resistant, corrosion-resistant, high-temperature oxidation-resistant, thermal barrier, electromagnetic shielding, insulating, and other functional coatings.
Common thermal spraying methods include flame spraying, arc spraying, and plasma spraying. The materials used range from metals and alloys to ceramics, cermets, and composite materials. These techniques have found widespread applications in aerospace, metallurgy, power generation, military equipment, petrochemicals, machinery, transportation, and bioengineering.
Most functional coatings produced via thermal spraying are used for surface protection, reinforcement, or repair. However, fewer studies focus on parts directly manufactured using thermal spraying. This paper explores the use of thermal spraying in the production of sliding bearings, highlighting the potential of this technique for creating specialized components.
**1. Conventional Manufacturing of Sliding Bearings**
Sliding bearings are essential mechanical components consisting of a rotating journal and a fixed housing. The inner part of the housing, known as the bearing bush, is typically made from bearing alloys, bronzes, aluminum, or zinc-based alloys. These materials are chosen for their excellent wear resistance, plasticity, and ability to run-in smoothly. However, they tend to be expensive and have lower strength compared to steel or cast iron. Most bearing housings are manufactured using centrifugal casting.
**2. Thermal Spraying for Sliding Bearing Linings**
In recent years, thermal spraying has been explored for producing bearing linings. For example, German automakers have developed patents for plasma-sprayed aluminum bronze coatings in engine connecting rods. However, due to limitations in current thermal spraying equipment, it is difficult to apply coatings to small internal holes (less than φ35 mm) or deep cavities.
This paper presents a new method for manufacturing sliding bearing linings using thermal spraying. A special tooling was designed with a mandrel, nuts, and a baffle made from low-melting alloy. The process involved depositing the bearing alloy on the mandrel, followed by a refractory coating. After spraying, the tooling was removed by heating the low-melting alloy, leaving behind a bearing lining.
The resulting bearing lining is an amorphous alloy with higher hardness than the base material and some porosity, allowing it to retain lubricants. This makes it superior to traditional cast bearings. Additionally, thermal spraying allows for thinner layers, reducing the use of valuable metals.
**3. Key Considerations in Thermal Spraying**
When applying thermal spraying to produce sliding bearings, several factors should be considered:
- **Material Selection:** Choose appropriate coating materials and spraying parameters based on operating conditions. For instance, nitrogen can be used as a spray medium to reduce oxidation.
- **Surface Finish:** If precision and roughness are required, the coating thickness and tooling dimensions must be carefully controlled to allow for machining.
- **Coating Adhesion:** Ensure proper adhesion between the base coating and the supporting layer. Residual stress and thermal expansion differences must be managed, possibly through intermediate layers.
- **Tooling Design:** The tooling should be easy to assemble and disassemble, and reusable. A release agent should be applied before spraying to prevent unwanted coating buildup.
**Conclusion**
This article demonstrates how thermal spraying can be used to produce sliding bearing linings, offering a viable alternative to traditional casting methods. While not suitable for mass production, this technique is ideal for custom or small-batch parts requiring special functionality. Future research could explore its application in other complex components such as hydraulic valves, cooling channels, and more.
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