Design of Cu-based powder alloys used for low speed and heavy bearing with inverse design methodology
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摘要: 基于需求导向, 采用逆向设计思想设计和开发了低速重载轴承用材料。首先, 利用有限元分析方法对低速重载滑动轴承服役条件进行分析, 获得了该服役条件下对材料性能的需求; 然后, 依据性能需求指标, 通过Ashby法绘制材料性能图, 并对各种可用材料进行比较和筛选, 确定Cu12Al6Ni5Fe铜基合金作为轴承材料; 最后, 采用粉末冶金法制备Cu12Al6Ni5Fe合金, 获得的合金强度为340MPa, 硬度HB 138, 达到了预期目标, 并通过对合金显微组织的分析, 提出了进一步改进思路。Abstract: Based on the demand oriented, the inverse design methodology was used to design the material used for low speed and heavy duty bearing in this paper. Firstly, the finite element analysis was performed to confirm the service condition of the low speed heavy duty sliding bearing, getting the properties of the material requirements under the service conditions. Then, the diagram of material properties was drawn by the Ashby approach, and the Cu12Al6Ni5Fe Cu-based alloys were selected as the bearing materials after comparison and screening. Finally, the Cu12Al6Ni5Fe alloy was prepared by powder metallurgy method, the alloy strength reached 340 MPa and the hardness was HB 138, which reached the expected target. According to the analysis of the alloy microstructure, the further improvement ideas were propose.
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图 1 滑动轴承转动过程受力分析：（a）第二主应力；（b）第三主应力
Figure 1. Force analysis of sliding bearing during rotation: (a) secondary principal stress; (b) third principal stress
图 3 部分材料性能及价格图：（a）滑动摩擦系数与归一化磨损率常数；（b）线性膨胀系数与导热系数；（c）断裂韧性与强度；（d）材料与硬度；（e）材料与价格
Figure 3. Properties and price maps of some materials: (a) coefficient of sliding friction and normalized wear rate; (b) thermal diffusivity and thermal conductivity; (c) fracture toughness and strength; (d) material and hardness; (e) material and price
图 4 铜合金性能和在无润滑条件下铜合金的摩擦系数：（a）屈服强度与硬度；（b）摩擦系数
Figure 4. Properties and friction coefficient without lubrication of copper alloys: (a) yield strength and hardness; (b) friction coefficient
图 5 铝质量分数对Cu–Al合金性能的影响：（a）硬度；（b）抗拉强度
Figure 5. Effect of aluminum mass fraction on the properties of Cu‒Al alloy: (a) hardness; (b) tensile strength
图 6 原料粉末颗粒的形态：（a）Cu；（b）Al；（c）Ni；（d）Fe
Figure 6. Morphology of the as-received elemental powders: (a) Cu; (b) Al; (c) Ni; (d) Fe
图 7 Cu12Al6Ni5Fe合金的金相微观结构
Figure 7. Metallographic microstructure of Cu12Al6Ni5Fe alloys
图 8 Cu12Al6Ni5Fe合金扫描电子显微形貌：（a）二次电子图；（b）局部放大图
Figure 8. SEM images of Cu12Al6Ni5Fe alloys: (a) secondary electron image; (b) enlarged image
表 1 滑动轴承服役需求参数
Table 1. Demand parameters of bearing service
轴套尺寸/ mm 面压/ MPa 滑动速度/ (m·min-1) 试验时间/ h 磨损量/ mm 硬度，HB 外径50，内径40，长30 80 < 1 60 ＜0.05 125~175 
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表 2 常温下合金元素在铜中最大固溶度时晶格常数[20]
Table 2. Lattice constants at the maximum solid solubility of alloying elements in copper at room temperature
固溶元素 最大固溶度（原子数分数）/ % 晶格常数（最大固溶度）/ nm Sn 0 3.6074 Mg 3.13 3.6345 Mn 4.50 3.6200 Cr 0 3.6074 Al 19.00 3.6563 Zn 38.00 3.6930 Fe 0 3.6074 Si 8.30 3.6131
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表 4 合金元素对铝青铜组织和性能的影响[40]
Table 4. Effect of alloying elements on the microstructure and properties of aluminum bronze[40]
合金元素 组织 性能 Fe 减缓共析转变，形成Fe3Al作为结晶核心，细化晶粒 提高强度、硬度、疲劳极限和耐磨性，过量的Fe则降低耐蚀性 Mn 缩小α相区，稳定β相，含量高时共析转变温度降到室温以下 提高强度、韧性和耐蚀性 Ni 扩大α相转变温度，提高共析细化晶粒，形成强化相 提高强度、硬度、耐磨耐蚀性和热稳定性 Zn 溶入α固溶体，减少镍铝青铜中铁微粒的数量 降低耐磨性、耐蚀性和塑性 Sn 少量溶入固溶体，扩大β相区 提高硬度、耐蚀性和防污能力，降低塑性 Cr 形成化合物 提高硬度、降低塑性阻止退火时晶粒长大 Pb 以游离态存在 降低塑性和韧性 P 形成磷化物 降低塑性和韧性
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表 5 Cu12Al6Ni5Fe合金中各相的能谱分析（质量分数）
Table 5. EDS analysis of each phase in Cu12Al6Ni5Fe alloy %
相组成 Cu Al Ni Fe α 82.47 10.82 4.74 1.97 KI 5.07 7.97 6.18 80.78 KII 46.39 12.77 5.37 35.47 NiAl 43.36 22.91 27.42 6.31 γ2 73.92 16.82 7.25 2.02
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