Zinc-free spray powder, copper-containing thermal spray layer, as well as method of manufacturing a copper-containing thermal spray layer
The invention relates to a zinc-free spray powder for thermally coating a substrate, in particular for thermally coating a bearing part of a bearing apparatus, which spray powder has the following composition except for unavoidable contaminants: tin=5% to 30% weight percent; aluminum=0.1% to 5% weight percent; iron=at most 1% weight percent, and copper=difference to 100% weight percent. The invention furthermore relates to a layer system applied via thermal spraying, a work piece, particularly a connecting rod, as well as a spray method for manufacturing a spray layer.
1. A zinc-free thermal spray coating powder consisting essentially of:
15 to 25 wt % tin;
0.1 to 5 wt % aluminum;
at most 1 wt % iron; and
remainder copper.
2. The powder of claim 1 , wherein:
tin is 20 wt %.
3. The powder of claim 1 , wherein one of:
aluminum is 0.5 to 2 wt %; or
aluminum is 1 wt %.
4. The powder of claim 1 , wherein one of:
iron is at most 0.5 wt %; or
iron is at most 0.2 wt %.
5. The powder of claim 1 , wherein said powder has a particle size of one of:
between 5 μm and 120 μm; or
between 10 μm and 60 μm.
6. A method of making the powder of claim 1 , wherein said method comprises:
forming said powder via one of:
gas atomization;
water atomization;
sintering;
flash drying; or
mechanical alloying.
7. A zinc-free layer system comprising:
a surface layer consisting essentially of:
15 to 25 wt % tin;
0.1 to 5 wt % aluminum;
at most 1 wt % iron; and
remainder copper.
8. The layer system of claim 7 , wherein the surface layer is one of:
a bearing layer;
a layer of a bearing part.
9. The layer system of claim 7 , wherein:
tin is 20 wt %.
10. The layer system of claim 7 , wherein:
aluminum is 0.5 to 2 wt %; or
aluminum is 1 wt %.
11. The layer system of claim 7 , wherein one of:
iron is at most 0.5 wt %; or
iron is at most 0.2 wt %.
12. The layer system of claim 7 , wherein the surface layer has a porosity of one of:
between 0.5 volume percent and 5 volume percent; or
between 1 volume percent and 3 volume percent.
13. The layer system of claim 7 , further comprising a top layer one of:
comprising tin; or
consisting essentially of tin.
14. A workpiece comprising the layer system of claim 7 .
15. The workpiece of claim 14 , wherein the workpiece is a piston connecting rod.
16. A method of thermal spraying the workpiece of claim 14 , comprising:
thermal spraying the powder of claim 1 onto the workpiece.
17. The method of claim 16 , wherein the thermal spraying comprises one of:
atmospheric plasma spraying;
vacuum plasma spraying;
HVOF spraying;
flame spraying; or
cold gas spraying.
18. A zinc-free thermal spray coating powder for forming a coating layer, said powder comprising:
a particle size between 5 μm and 120 μm; and
a composition consisting essentially of:
15 to 25 wt % tin;
0.1 to 5 wt % aluminum;
at most 1 wt % iron; and
remainder copper.