Aluminium matrix bearing metal alloy

Abstract: An aluminium alloy is prepared from an aluminium alloy powder having composition of: lubricating component Pb: 3 to 15 Wt%; Sn: less than or equal to 5 Wt%; hardening component Si: 1 to 12 Wt%; reinforcement component one or more selected among Cu, Cr, Mg, Mn, Zn, Fe: 0.2 to 5.0 Wt% and, remainder of aluminium as principal material or matrix; To the aluminium alloy powder set forth above, powder state Pb in 3 to 12 Wt% is added. With the mixture of the aluminium alloy power and Pb power, a billet is formed. For the billet, extrusion process is performed in a extrusion ratio greater than or equal to 40. In the extruded block, Si particle dispersed in the aluminium matrix is in a grain size smaller than or equal to 12 µm. Furthermore, at least of half of added Pb power particle is dispersed on the sliding surface of the aluminium matrix to have greater than or equal to 0.74 of circularity coefficient which is derived from the following equation: circularity coefficient = 4Ö x (surface area of block)/(circumferential length) In case that the bearing metal is required substantially high wear-resistance, Pb phase and/or Pb alloy phase having 50 µm of average grain size occupies greater than or equal to 85% of area ratio versus overall Pb phase and/or Pb alloy path.

Description: BACKGROUND OF THE INVENTION Field of the Invention The present invention relates generally to an aluminium type alloy having high wear-resistance, fatigue-resistance and so forth and having light weight. More specifically, the invention relates to an aluminium type alloy suitable for use as bearing metal for producing bearings, sliding member and so forth for automotive vehicles, industrial machines, agricultural machines and so forth. Description of the Background Art Various bearing metals, such as Cu-Pb type metal alloy, babbitt metal and so forth are selectively used as material for producing slip bearing depending upon use of the bearing. In the automotive industries, attention has been attracted to an aluminium type alloy for bearing metal for bearings employed in an internal combustion engine, for its high heat-resistance, wear-resistance, corrosion-resistance, fatigue-resistance and so forth. Particularly, Aℓ-Sn type alloys, Aℓ-Sn-Pb type alloys have been considered to have better or more suitable property for use in automotive internal combustion engine. On the other hand, in the recent days, the automotive internal combustion engines have been required smaller size and lighter weight. To answer such requirement, components of the engine have become smaller. Naturally, an axial length of the bearings are reduced. In contrast to this, the modern type engine have been grown to produce higher power for higher performance. This subjects the bearings in the engine much severe condition. Such severe condition of use of the bearing encounters various problems. Namely, under severe condition of use in the modern and high performance engine, formation of crack, local spolling from backing steel becomes serious problems. Therefore, providing sufficiently high fatigue-resistance becomes important task. In order to anwswer this, the owner of the present invention has disclosed new type bearing metal in GB-A-2,185,041 corresponding to JP-A-62-130253. The proposed material is generally composed of Aℓ-Sn-Pb type alloy which is formed into atomized alloy powder. The alloy power is processed through extrusion process. The proposed bearing metal has substantially high fatigue-resistance and high lubricating ability. The proposed alloy is composed of Aℓ as a matrix or principal component; one or more selected among Pb, Sn, In, Sb, Bi as lubricating component; Si as hardening component; one or more selected among Cu, Cr, Mg, Mn, Ni, Zn, Fe as reinforcement component. The lubricating component is added so that the area ratio versus Aℓ matrix is in a range greater than 0.04 and smaller than or equal to 0.07. The hardening component is added so that the area ratio versus Aℓ matrix is in a range of greater than or equal to 0.01 and smaller than or equal to 0.17. The reinforcement component is added in a content of 0.2 to 5.0 wt%. Further, if desired, one or more selected among Ti, B, Zr, V, Ga, one or more rear earth metal (REM) including Sc and Y can be added in a content of 0.01 to 3.0 Wt% to composite alloy. The lubricating component is prepared in a form of fine grain powder having grain side less than or equal to 8 µm. The power state lubricating component is uniformly dispersed in the power state alloy. The power state alloy is formed into a billet and processed through extrusion process in an extrusion ratio of greater than or equal to 10. The grain size of Si as hardening component is controlled to be smaller than or equal to 12 µm, preferably in a range of 6 µm to 12 µm. The extrusion processed alloy has tensil stress greater than or equal to 12 Kgf/mm at normal temperature and has expansion under normal temperature is 11% in tensil test. In such metal alloy, it is preferable to contain large content of Pb as lubricating component for better lubricating ability and higher heat-resistance, higher wear-resistance, higher corrosion-resistance, better oil affinity and so forth. However, when the content of Pb in the alloy exceeds 12 Wt%, Pb grain size becomes excessively large and Pb segregation is caused in the atomized powder processed from the metal at practically used temperature. Furthermore, due to gravitical segregation, fluctuation of Pb concentration can be caused. Excessive grain size of Pb tends to degrade fatigue-resistance of the alloy. Furthermore, due to fluctuation of content of Pb, local degradation of burning or seizing resistance or fatigue-resistance is caused in the alloy. In such reason, the content of Pb is limited to be smaller than or equal to 12 Wt%. In order to provide Pb content, attempt was made to prepare powder state Pb separetely from Aℓ alloy powder. The Pb powder is added to the Aℓ alloy powder before extrusion. However, this attempt was not so successful because when Pb content in excess of 12 Wt% is added, liquid phase Pb molten by the heat in the extrusion process tends to bind Pb particles for forming excessively large size Pb grain in the alloy. Furthermore, presence of such liquid state Pb tends to cause extrusion defect in the extruded block. DISCLOSURE OF THE INVENTION In view of the state of art as set forth above, it is an object of the invention to provide an aluminium type bearing metal which has satisfactorily high fatigue resistance and burning or seizing resistance,and which has optimum lubricating properties. In order to accomplish the aforementioned object, an atomized aluminium type bearing metal is prepared as defined in claim 1. A preferred embodiment of the bearing metal defined in claim 1 is given in the dependent claim. Said circularity coefficient is derived from the following equation: circularity coefficient = 40 x (surface area of block)/(circumferential length) In case that the bearing metal is required substantially high wear-resistance, Pb phase and/or Pb alloy phase having 50 µm of average grain size occupies greater than or equal to 85% of area ratio versus overall Pb phase and/or Pb alloy path. As will be appreciated herefrom, the problem of larger content of Pb which has been caused in the prior art can be solved by the present invention by originally providing a limited content of Pb for obtaining uniform distribution of fine particle Pb in the material alloy powder and by adding acceptable amount of Pb, which amount in limited so as not to degrade workability in extrusion process. Furthermore, by appropriately setting extrusion condition, distribution of Pb particle on the sliding surface becomes approximately in circle. In particular, the extrusion process is so controlled for adjusting growth of Si particle that Si particle dispersed in the aluminium matrix is in a grain size smaller than or equal to 12 µm. Furthermore, the extrusion process is so controlled that Pb power particle is dispersed on the sliding surface of the aluminium matrix to have greater than or equal to 0.74 of circularity coefficient. The extrusion process is so controlled that Pb phase and/or Pb alloy phase having 50 µm of average grain size occupies greater than or equal to 85% of area ratio versus overall Pb phase and/or Pb alloy path. The atomized aluminium alloy powder is prepared from a metal at a practical melt temperature. Pb being distributed on the surface of the aluminium matrix so as to achieve greater than or equal to 0.74 of circularity coefficient on a bearing surface mating with a rotary body supported thereon. Further detail about present invention will be discussed herebelow for facilitating better understanding of the invention. However, the present invention will be understood more fully from the detailed description given herebelow and from the examples given herebelow, the invention should not be taken to limit the invention to the specific examples but are for explanation and understanding only. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: Sole drawing shows explanatory drawing showing load pattern in wearing test. DETAILED DESCRIPTION OF THE INVENTION The present invention will now be discussed in detail with reference to some examples derived from experiments. At first, discussion will be made for composition of an aluminium alloy which will be hereafter referred to as "material Aℓ alloy" as a base or principal material for producing a bearing metal according to the present invention. (1) Lubricating Component In the present invention, material Aℓ alloy contains a limited amount of lubricating component for providing high wear-resistance, fatigue resistance and so forth. Amongest various material to be used as lubricating component, the present invention selects Pb and Sn as preferred materials. Both of these materials are known as appropriate materials for providing lubricating ability. Furthermore, in comparison with Sn, Pb has better property in view point of bearing or seizing resistance ability. When Pb content is less than 3 Wt%, burning or seizing resistance ability becomes unacceptably low. In addition, at such low content of Pb, ability of burying foreign matter becomes acceptably lowered. On the other hand, when the content of Pb becomes in excess of 15 Wt%, fatigue-resistance of the matrix becomes lowered. Therefore, in either case, the material cannot be regarded suitable as bearing metal for insufficient withstanding load. In addition, when the content of Pb becomes greater than 12 Wt%, grain size of Pb particle in Pb phase in atomized powder which is produced from practical temperature range of melt, becomes excessively large. Furthermore, the Pb content greater than 12 Wt% may cause segregation of Pb in the matrix. Such excessive grain size of Pb particle or segregation cause in the matrix influences to property of extruded block even when extrusion rate is rather large. Therefore, preferred content of Pb is less than or equal to 12 Wt%. On the other hand, Sn is effective for improving corrosion-resistance of Pb. However, if the content of Sn is greater than 5 Wt%, fatigue-resistance becomes insufficient. Furthermore, Sn in excess of 5 Wt% may become liquid phase by heat during extrusion process to form defect in the extruded block. In view of this, the content of Sn is limited less than or equal to 5 Wt%. (2) Hardening Component In the shown invention, Si is used as hardening material for the material Aℓ alloy. Si is thus added in a form of eutectic crystal Si or pre-eutetic crystal Si. Si is thus added for improving mechanical strength of the bearing metal and wear-resistance. When the content of Si is smaller than 1 Wt%, remarkable effect of Si cannot be obtained. On the other hand, when the content of Si is greater than 12 Wt%, toughness of is reduced for degrading workability. Grain size of Si particle is preferred to be less than or equal to 12 µm. When the grain size of Si particle becomes greater than 12 µm, such great grain size Si particle tends to damage other materials in the extruded block. Furthermore, Si particle having grain size greater than 12 µm tends to cause insufficient area density to cause degradation of wear-resistance. Therefore, Si content is limited to be smaller than or equal to 12 µm. It is also possible to add Si in a form of atomized Si powder containing Aℓ in a content of 8 Wt% to 30 Wt%. (3) Reinforcement Component Material Aℓ alloy further contains reinforcement component for improving strength of the alloy. In the present invention, the reinforcement component is composed of one or more materials selected among Cu, Cr, Mg, Mn, Ni, Zn and Fe. Such reinforcement component is preferred to be contained in a range of 0.2 Wt% to 5.0 Wt%. Amongest the material set out above, Cu is considered good material for high creep strength. Therefore, Cu may provide high fatigue-resistance at high temperature sliding. If the content of Cu is less than 0.2 Wt%, noticeable improvement in creep strength cannot be expected. On the other hand, if the content of Cu is greater than 5.0 Wt%, large amount of needle form CuAℓ is precipitated to cause degradation of toughness. This causes lowering of fatigue-resistance. Cr, Mg, Mn, Ni, Zn and Fe have equivalent property to that of Cu and often used as additive for providing malleability of Aℓ alloy. Therefore, one or two of these materials are added as reinforcement component in a range of 0.2 Wt% to 5.0 Wt%. (4) Material for Fine Crystallization of Alloy. If desired, in addition to the foregoing components, material which aids for fine crystallization of material Aℓ alloy, can be added. In the present invention, such material is selected among Ti, B, Zr, V, Ga, REM (including Y and Sc). The material is added in amount of 0.01 Wt% to 3.0 Wt%. Such material is particularly effective in promoting fine graining of particle of lubricating component. Aforementioned components (1) through (4) are added to Aℓ matrix and processed for preparing atomized Aℓ powder. According to the present invention, Pb powder prepared separately from the material Aℓ power set forth above, is added before performing extrusion process. Composition of the Pb power will be discussed hereinbelow: (5) Pb in the Pb powder Pb in the Pb powder serves as lubrication for providing anti-buring or anti-seizing property for Aℓ alloy as the bearing metal. If the amount of Pb to be added is less than 3 Wt%, noticeable lubricating effect cannot be obtained. On the other hand, if the amount of Pb to be added is greater than 12 Wt%, the added Pb powder is at least partly molten to degrade extrusion ability. Furthermore, grain size becomes excessively greater by coupling Pb particles to each other. During extrusion process, Pb particle is crushed into smaller grain size. However, in order to obtain fine grain of Pb as equivalent to that in the material Aℓ powder, it is preferably to use Pb of grain size smaller than or equal to 300 mesh. According to the present invention, distribution of Ph phase and Pb alloy phase in the extruded block is so controlled as to have sufficiently high circularity. In case that distribution of Pb phase or Pb alloy phase in the extruded block is in a form or ellipsis or strip, uniformity of distribution of Pb cannot be obtained to cause burning or seizing when local contact between bearing metal and a shaft to be supported thereon is caused at the portion where Pb phase or Pb alloy phase is absent. Furthermore, such non-uniform distribution of Pb can lower strength versus load applied in a direction perpendicular to the Pb or Pb alloy phase to lower fatigue-resiistance. In addition fluctuation of distribution of Pb causes fluctuation of performance of respective independent extruded blocks. The inventors have found that when Pb particles as added in a form of the Pb powder is distributed on the sliding surface in a form having 0.74 of circularity coefficient which is derived from: circularity coefficient = 4Ö x (surface area of block)/(circumferential length) satisfactory anti-burning or anti-seizing property and fatigue-resistance of the bearing metal can be obtained. On the other hand, when the Pb or Pb alloy phase has too large size, it still possible to degrade fatigue-resistance. Therefore, when particularly high fatigue-resistance is required, average grain size of Pb and/or Pb alloy phase is better to be limited to be smaller than or equal to 50 µm. Practically, in order to obtain particularly high fatigue-resistance, it becomes necessary to provide area ratio of Pb and/or Pb alloy phase having average grain size smaller than or equal to 50 µm versus overall Pb and/or Pb alloy phase, greater than or equal to 85%. In order to perform extrusion process, the Pb power is added to the material Aℓ powder. With the mixture of the Pb powder and the material Aℓ powder, a billet is formed. The billet is then subject extrusion process in an extrusion ratio of 40. When the extrusion ratio is less than 40, satisfactorily high circularity of distribution of Pb or Pb alloy phase cannot be obtained. Furthermore, when extrusion is performed at the extrusion ratio less than 40, extrusion defects, such as internal crack or surface checking can be formed. In addition, in order to avoid deformation of extrusion defect, it is preferably to perform extrusion at a temperature lower than or equal to 450°C. EXAMPLES In order to demonstrate the property of the Aℓ type bearing metal produced according to the present invention, discussion will be made with respect to examples together with comparative examples, herebelow. The compositions of the examples and comparative examples are shown in the appended table I. Initially, respective sample materials No. 1 through No. 23 are subject air-atomizing process for obtaining material Aℓ alloy power. In the atomizing process, melts at a temperature of 1100 °C is prepared. For respective melts of samples No. 1 through No. 23 is then subject to air-atomization process. In atomized Aℓ powder produced by the sample No. 18, large number of segregated powder containing Pb and Sn as principal components was observed. For atomized powders of respective samples, Pb powder having composition as shown in the table I is added and mixed. The mixtures are formed into cylindrical billets having diameter of 200 mm, axial length of 150 mm. Billets were formed by green compacting at a pressure of 2.0 tonf/cm . The billets were wrapped by pure aluminium plate and then subject extrusion process into a plate form extruded body having thickness of 3 mm and width of 105 mm. During extrusion, the samples Nos. 20 and 21 were heated at 470 °C and remaining samples are heated at 400 °C. Because of excess amount of Pb in the material Aℓ alloy of sample No. 18, excess Pb content in Pb powder of sample No. 14, and excess amount of Sn in the material Aℓ alloy of sample No. 16, defects, such as surface checking or end crack, were observed. Therefore, the extruded blocks of these samples were not suitable for practical use. Sample No. 24 was prepared in the composition of: Si: 4 Wt% Cu: 1.00 Wt% remainder amount of Aℓ having particle size of 150 mesh The material Aℓ powder was mixed with Pb powder containing 30 Wt% of Sn. The material Aℓ powder and Pb powder were mixed in a ratio of 84 : 16. With the mixture, billet was formed by green compacting at a pressure 2.0 tonf/cm . The billet has the same dimension as that of other samples. The billet was wrapped by pure aluminium plate and subject extrusion for forming 25 mm-thick and 100 mm-width extruded body. Extrusion was performed at a process temperature of 280 °C. Friction Test The sample alloys Nos. 1 through 12 of the examples and Nos. 13, 15, 17, 19 through 24 of the comparative examples, which could formed into extruded bodies without causing defect, were subject several stages of rolling to form thin strips. From each strips, sample strips of 35 m-width, 35 mm-length and 1.5 mm-thickness was obtained. For sample alloy No. 24, intermediate annealing at 300 °C for 5 hours was performed at thickness of 10 mm and 4 mm during rolling process. Furthermore, final annealing at temperature of 350 °C for 5 hours was also performed before cutting the sample strip. For other sample alloys, only final annealing at the same condition. Alloy No. 15 caused cracket during rolling process and could not be rolled at the target temperature. For the sample strips, friction test in a condition as shown in the appended table XX and shown in the drawing was performed. The results of the friction test are shown in the appended table III. As can be clear from table III, the example No. 1 through 12 of the present invention had far better surface surface property than that of the comparative examples No. 13, 17, 19 through 24. Bearing Fatigue-Resistance Test For sample alloys of Nos. 1 through 12 of example and Nos. 13, 17, 19 through 24, with which healthy extruded blocks and rolled strips could be obtained, were subject rolling process with steel strip of 1.7 mm-thickness, at a reduction of 48%. Subsequently, final annealing at a temperature of 350 °C for 10 hours was performed. After annealing, each samples are machined to form bearings. For the bearings of respective samples, bearing fatigue-resistance test was performed under the severe condition as shown in table IV. Results of the bearing fatigue-resistance test are shown in the appended table V. As can be seen from the table V, the examples No. 1 through No. 12 according to the present invention, lowering of fatigue-resistance was not observed despite of increased amount of Pb and whereby improving of anti-burning or anti-seizing property. In contrast to this, comparative examples Nos. 20, 21 end 24 causes crack in a short period and this appreciated that these have insufficient fatigue-resistance. While the present invention has been disclosed in terms of the preferred embodiment in order to facilitate better understanding of the invention, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments which can be embodied without departing from the principle of the invention set out in the appended claims. Condition of Friction Test Dimension of Sample (mm) (V x W x T) 35 x 35 x 1.5 Peripheral Velocity (m/sec) 4.0 Kind of Fluid SAE 7.5W-30 Fluid Temperature (°C) 130 Material of Shaft S45C Shaft Roughness (Rmax µm) 0.8 Shaft Hardness (H R C) Approximately 55 Load Pattern (Fig. 1) 20 Kgf ∼ 400Kgf (or until Burning) 20Kgf/15min (Stepwise increase) Condition of Detection of Burning Material Temp. ≧ 220 °C or Ffriction Coefficient ≧ 0.3 Results of Friction Test No. Example Buring Load (Kgf) 1 Invention 280 2 Not Burnt 3 360 4 320 5 300 6 320 7 360 8 360 9 320 10 340 11 320 12 Not Burnt 13 Comparative 260 17 280 19 180 20 200 21 220 22 160 23 160 24 200 Condition of Fatigue Test Dimension of Bearing (mm) (Dia. x W x T) ⊘ 53 x 11.3 x 1.5 Rotation Speed (r.p.m.) 3500 Kind of Fluid SAE 20W-40 Supply Fluid TRemperature (°C) 130 Supply Fluid Pressure (Kgf/cm²) 4.0 Material of Shaft S45C Shaft Roughness (Rmax µm) 0.8 Shaft Hardness (H R C) = 55 Test Time (Hrs.) 200(or until Cranking) Results of Fatigue Test No. Example Fatigue Tme 1 Invention Not Fatuiged 2 140 3 180 4 160 5 Not Fatuiged 6 180 7 140 8 180 9 160 10 140 11 160 12 140 13 Comparative 180 17 140 19 Not Fatuiged 20 120 21 100 22 100 23 100 24 80

Claims: An aluminum-type bearing metal produced by preparing (i) an atomized aluminum alloy powder comprising (by weight) Pb: 3 to 15%; Sn: less than or equal to 5% as lubricating component; Si: 1 to 12% as hardening component; one or more elements selected from Cu, Cr, Mg, Mn, Ni, Zn and Fe: 0.2 to 5% in total as reinforcing component; optionally one or more elements selected from Ti, B, Zr, V, Ga, REM (including Y and Sc) in a total amount of 0.01% to 3.0% for promoting fine crystallization of the alloy the remainder being Al; (ii) adding a separately prepared Pb powder in an amount of 3 to 12% and, having a particle size smaller than or equal to 300 mesh, forming a mixture and extruding the mixture at an extrusion ratio of 40% or higher and at an extrusion temperature lower than or equal to 450°C, at least half of the added Pb powder particles being dispersed on the sliding surface of the aluminum matrix to have a circularity coefficient of 0.74 or higher and the Si particles being dispersed in the aluminum matrix in a grain size smaller than or equal to 12µm, and the Pb being distributed in a form of Pb phase and/or Pb alloy phase, such that at least 85% of the area occupied by said Pb phase and/or Pb alloy phase contains Pb or Pb alloy, having an average grain size of smaller than or equal to 50 micrometers. An aluminium type bearing metal as set forth in claim 1, characterized in that said Pb is distributed in a form of Pb phase and/or Pb alloy phase such that at least 85% of the area occupied by said overall Pb phase and/or Pb alloy phase contains Pb or Pb alloy having an average grain size of smaller than or equal to 50 micrometers.

Inventors: ARITA MASASHI, OHKAWA KOUE, SAKAI TAKESHI, SHIODA MASAHIKO, TANIZAKI KATSUJI, ARITA, MASASHI, OHKAWA, KOUE, SAKAI, TAKESHI, SHIODA, MASAHIKO, TANIZAKI, KATSUJI
Applicants: NIPPON DIA CLEVITE CO, NISSAN MOTOR, NDC CO., LTD., NISSAN MOTOR CO., LTD.
Application year: 1989
Main classification: C22C1
IPC codes: C22C1, F16C33, C22C21