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Recent Development of Plain Bearings for Combustion Engines

2013 ． Nov ． 19

Taiho Kogyo Co., Ltd.TTRF Yoshio KUMADA

MITC2013

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Contents

1 What is “Plain Bearing for Internal Combustion Engine”? 1.1 Short History 1.2 Needs & Direction of Development

2 Higher Performance, Lead Free 2.1 Al-Sn-Si(-Pb) Alloy Bearing 2.2 Microgrooved Bearing 2.3 Lead Free Overlay

3 Lower Fuel Consumption for Future 3.1 Bearing with Eccentric Oil Groove 3.2 Bearing with Surface Texture 3.3 Friction loss reduced by Fullerene/Graphene coating

4 Conclusion

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1 Plain Bearings for Internal Combustion Engine

Camshaft bearing

Con-Rod small-end bearing

Con-Rod big-end bearing

Crankshaft bearing

Crankshaft bearing

Con-Rod big-end bearing

Crankshaft

Con-RodSmall-end

Big-end

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Scientific Research – Modern age Scientific Research – Modern age

1687 　　 I. Newton “Principia” Newtonian fluid, viscosity law 1883 B. Tower 　　　　　 experimental work 　　　

　　 - discovery of oil film pressure1886 O. Reynolds theoretical work 　　　　　　 - Reynolds’ equation1902 R. Stribeck Stribeck curve 　　　　　　

1904 A. J. W. Sommerfeld analytic solution of Reynolds’

equation1904 A. G. M. Michell tilting pad bearing (patent)

1910 A. Kingsbury 　　　　　　　　　

1.1 Short History

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1839 　 ～ 　 　　　

　　　　 1908 　　　　　　　　　　　　　　　

J.Babbitt invention of White metal (1839, USA Patent)Babbitt metal (Sn-9Sb-2Cu)

T-type Ford, from 1908

White Metal・ Tin base (Sn-Sb-Cu-Pb) Lead base (Pb-Sb-Cu-Sn)

Soft, Low melting point Good : conformability, Anti-

seizurePoor : heat resistance, Anti-

Fatigue

Modern age – Modern age – White MetalWhite Metal

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1920s Higher Load Carrying Capacity & Fatigue Resistance　 　　　　　　 Soft lead phase dispersed in hard metallic matrix　　　　　　　 　　　⇒　 Basic concept of recent bearing materials　　　　　　　 thick-walled cast Cu alloy with 20-50%Pb　　　　　　　 afterward,

centrifugal casting or direct casting on back-steel1939 　　　 Powder metallurgy : continuous sintering on back-steelAround Widely Expanded 1940 – quality, productivity, economic efficiency afterward, Cu-Pb with Overlay (electroplated, 20μm) 　　　　

Copper-Lead, OverlayCopper-Lead, OverlayModern age – Modern age –

Higher conformability & Anti-seizurearound 　　 Pb-Sn-Cu, Pb-Sn, Pb-Sn-In, Pb-In 　　　　　 　 1970 Ni intermediate layer 　　　　　　　

20μm

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World War I Lack of Heavy Metals

1920s Rolls-Royce(GB) thick-walled cast duralumin with

Overlay, C/R, P/P1930s 　　 USA Al-6Sn with Sn Overlay 　 VW(DE) Al-5Zn-SiCuPbMg1950s 　　 USA Bimetal 　　　　　　　　 GB Al-20Sn without Overlay 　　

　　　　1970s USA, JPN Al-Pb Casting, Powder sintering

Aluminum AlloyAluminum AlloyModern age – Modern age –

Al-20Sn

As Cast Bimetal

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Pb-6In-7Sn/Cu-23PbBack Steel

Bearing alloy(Lining)

Cu-Pb alloy bearingwith overlay

Al-12Sn-2.7Si-1Cu(-2Pb)

20μm

OverlayNi barrier

Cu-Pb alloy

Structure of Engine Bearing and Cross-Sectional View

20μm

back steel

Al alloy bearing

back steel

Bearing lining Bearing lining

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1.2 Needs and Direction of Development1.2.1 Bearing Pattern

Prof. Norimune Soda said, “There is an effective method of using bearings, which is called the bearing law, that is the Bearing pattern”.軸受には軸受法という法則があり，当たりこそ軸受法である．（曽田先生）

＃ 1 　　　 ＃ 2 　　　 ＃ 3 　　　 ＃ 4

Severity of engine bearings

Maximum unit load : Pmax = 50 -100 MPa

Minimum oil film thickness : hmin = 0.4 - 0.8 μm

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Ref. : Y. Kumada, Journal of Japanese Society of Tribologist ， 41, 1 (1996) 28

1.2.2 Conformability, Running-inDevelopment of Bearings ・・・ the challenging theme how to make running-in of the bearing materials with higher strength

１　 Thin Overlay

２　 Hard Particle in the Lining

３　 Softer Middle Layer

４　 Micro Regular Shape in the Surface

Pb base Overlay

Pb Free

2.3 Pb free Overlay

2.1 Al-Sn-Si Alloy

2.2 Microgrooved Bearing

Al-Sn-Si Alloy + Underlay

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2.1 Al-Sn-Si alloy, 2.2 Microgrooved Bearing(2.3 Lead Free Materials)

(2.2 Microgrooved Bearing)(2.3 Lead Free Overlay)3.1 Eccentric grooved Bearing3.2 Surface texture

・ Higher Oil Temp.・ Higher Unit Load

2.2 Microgrooved Bearing

・ Higher Durability・ Lower cost

High performance

Improve of Fuel Consumption

Clean Exhaust Gas

Reduction of Noise & Vibration

Otherslonger life, cost reduction

Reduction of Environmental Substances of Concerns

2.3 Lead Free Materials

1.2.3 Trends of Engines & Influences on Bearing

Trend of Engines Influences on Bearing → Solution

・ Higher Unit Load

・ Lower Rigidity of Housing・ Narrow Width → Higher Unit Load・ Lower Viscosity Oils・ Excessive wear

・ Smaller Diametral Clearance

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2.1 Al-Sn-Si Alloy Bearing

2.1.1 Seizure by Nodular Cast Iron Shaft

Ref. : T. Fukuoka, H. Kato, S. Kamiya, N. Soda, SAE Technical Paper, 830308 (1983)

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2.1.2 Lapping shaft surface by hard particles, Si

Ref. : T. Fukuoka, H. Kato, S. Kamiya, N. Soda, SAE Technical Paper, 830308 (1983)

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Fig. seizure property of two kinds of Al-alloy bearings

Fig. seizure process of Al-alloy bearings and new concept

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Al-12Sn-2.8Si

normal

Larger Si

GO-STOP 50kcycles2.2MPa120C ATFSCM420H carburizing & quench

0

20

40

60

80

100

1 2 3 4 5

Wear

am

ount

，m

m

Si Mean particle size, mm

2.1.3 larger Si particle Size （ 2→ 5μm ）

Ref. : T ． Desaki et al., JSAE Review, 21, 3 (2000) 321.

20μm

20μm

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0.1 ～ 0.4 mm

3 ～ 6 μm

３

2.2 Microgrooved Bearing （ MGB)

Ref. : Y. Kumada, Dissertation in The University of Tokyo （ 1996 ）

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2.2.1 Al alloy bearings (after engine endurance test)　　　　　 Look at the bearing pattern ！

Microgrooved Bearing Normal Plain Bearing

＃ 1 　　　 ＃ 2 　　　 ＃ 3 　　　 ＃ 4 ＃ 1 　　　 ＃ 2 　　　 ＃ 3 　　　 ＃ 4

Blo

ck sid

eC

ap

side

Engine: V6,3.0L 6,300r/min×WOT ×100h

Bearing:Crankshaft bearing Al-Sn-Si alloy

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2.2.2 Bearing temperature rise

Test condition

Engine ： I-6, 2000cc, gasoline#4 crankshaft bearing was measuredLoad ： W.O.T.Lubricant ： 7.5W-30 　 SEOil temperature ： 130℃

140

160

180

Rotational speed, r/min

Beari

ng

back

sid

e t

em

p.,

℃

5000 6000 7000 8000

MGB G24 MGB G23 NPB

Seizure

Al-Sn-Si alloy NPB

Al-Sn-Si alloy MGB G24

Lead Bronze with Overlay

NPB

ΔT ＝ kQ/G Oil flowHeat generation

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Ref. ： Y. Kumada et al., Tribology Trans., 39, 1 (1996) 81

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■Contribution to improving fuel consumption, lower cost et al.

●Received the first JAST award　　　　　　　　　　　　　　　　　　 (1996. 5)

Main stream of Engine Bearings（ around 75% of worldwide Taiho engine bearings ）

It is common that a plain bearing hasplane surface in order to carry the load by oil film pressure.

An engineer of Taiho Kogyo in which I have taught Tribology for forty years, proposed the idea in a confident attitude. “The idea, whichSurface has many grooves, is not common. That is very interesting.”

2004.2.24 Asahi Newspaper

Prof. Kimura says,

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2.3 Lead Free Materials2.3.1 Lead Amount of Typical Plain Bearings

Pb amount in a piece of bearing (mass%)

White Metal

Overlay

Al alloy

Cu alloy

Sn basePb base

Pb baseSn base

Al-SnAl-Sn-Si-PbAl-Pb-SiAl-Zn-Si-PbAl-Cd

Cu-Pb-SnCu-SnCu-Graphite

Category Composition 1 2 3 4 5 6 7 8 9

OverlayLining

Back steel

Ref. ： S. Kamiya, Document of 47th Contingence-Composite session meeting, JSTP (2001)

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2.3.2 Pb Free Bearing Materials

Taiho Kogyo other companies

Aluminum Alloy

Overlay

Copper Alloy

Overlay

Al-20Sn-1Cu Al-(12-15)Sn-3Si-1Cu-Cr,Zr,V,Mn Al-(6-7)Sn-3Si-(1-1.5)Cu-Cr,Zr,V,Mn

Al-(4-5)Zn-Si-Cu

PAI-72MoS2 (Solid PAI-(18-20)MoS2-(10-18)Gr,WS2

Lubricant Overlay) PTFE-MoS2-Gr

Cu-4Sn-7Bi Cu-(4-10)Sn-(4-8)Bi-Mo2C,Zn,NiCu-6Sn-Ag Cu-(5-8)Sn-Ni,P Cu-20Zn-Ni,Al,Mn,Fe

PAI-72MoS2 (S.L.O) Sputter (Al–20Sn)Bi Bi/Ag, BiSn Sn-(2-8)Cu

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2.3.3 Solid Lubricant Overlay PAI+MoS2

Good conformability for initial running-in Low friction by solid lubricant, MoS2 PAI(thermosetting resin) for binder + MoS2 (solid lubricant) 40vol% Thickness 6μm

Good conformability for initial running-in Low friction by solid lubricant, MoS2 PAI(thermosetting resin) for binder + MoS2 (solid lubricant) 40vol% Thickness 6μm

Cross-section of Overlay

Overlay

“Pb free bearings”JSME “Technology Award” in 2003

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Al-7Sn-2.7Si-1.5Cu-Cr-Zr/PAI-72MoS2

better

Fatigue resistance of Al-Sn-Si alloy bearing with solid lubricant overlay

Ref. ： Y. Kumada et al., VDI-Berichte Nr. 1906 （ 2006 ） 113

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Touareg

Adopted for VW W12 crankshaft bearings

Ref. : R.Szengel, F.T.Metzner & M.Dehmke, Aachener Kolloquium. “Fahrzeug und Motorentechnik” (2003)

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Ref. : Nikkei Monodukuri ， 8 (2012) 92.

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Taiho Kogyo developed Crankshaft bearings having super low frictional property for Mini-vehicle -- Bearings with solid lubricant overlay --

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•Al-Sn sputter (GB, DE, Austria)

　 Higher Load Carrying Capacity

Slightly Lower Conformability

High production Cost (PVD)sputteredAl-20Snoverlay

Cu-Sn alloySputter (SEM Image)

2.3.4 Al-Sn Sputter

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3.1 Eccentric oil-grooved bearing for low fuel assumption

Conventional Eccentric

Oil flow in oil groove

parti

ng e

nd

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Ref. : Y. Hikita et al., ITC KOBE 2005, Book of Synopses (2005) 24.

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Ratio of friction loss

Piston & Con-rod

Accessory

Valve train Crankshaft

Oil pump 16%

Water pump

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3.1.1 Background

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Engine : L4 1.5LOil temperature : 100ºC

0

10

20

2000 4000 6000Rotational speed , rpm

Oil

flow

, L

/min

Crankshaft bearing

Connecting rod bearing

Valve train

Crankshaftbearing (Upper)

Connecting rod bearing Upper Lower

Crank pinjournal

Crank main journal

Crankshaftbearing (Lower)

Crushrelief

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Conventional Eccentric

Oil flow in oil groove

largeSide flow is

parti

ng e

nd

reduced

Crush relief area(Clearance is large)

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3.1.2 Eccentric oil-grooved bearing

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-0.2

-0.1

0

0.1

2 4 6 8 10Oil flow , L/min

Fric

tion t

orq

ue d

iffere

nce

,

Nm

Conventio

nal

No. 1

No. 2

No. 3

Eccentri

c

q0º

90º

Partin

g

end

Oil groove end

Cen

ter

0

0.2

0.4

0.6

0.8

1

1.2

0 30 60 90 θ , º

Depth

, m

m

Conventional

No. 1

No. 2

No. 3

(Center) (Parting end)

30

3.1.3 Relationship of oil groove end and friction torque

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4 Conclusion & Future Issues

1 Al-Sn-Si alloy, Microgrooved Bearings were adopted in almost all automotive engines, and have become standard ones.

2 Regarding Lead free bearings, we have to develop high performance engine bearings, that is, the bearings satisfying both of running-in property and material hardness.

3 It is desired that mechanical loss caused by bearing friction will be near zero, so near zero friction bearings have to be developed near future.

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34 表４ 同一排気量（１５００ｃｃ）エンジンの年代毎の軸受負荷容量の変化

年代 ｴﾝｼ ﾝ゙型式 出力 重量 適用車種 軸受寸法 軸受材質 内部構成部品 備考

1960 Ｒ型 PS６０ １６６Ｋｇ コロナ

:Φ × ×Ｍ／Ｎ（１） ６１．６ ３０ １．７９:Φ × ×Ｍ／Ｎ（２） ６１．６ ３４ １．７９:Φ × ×Ｍ／Ｎ（３） ６１．６ ４０ １．７９

Φ × ×Ｃ／Ｒ： ５３ ２７ １．５０/ 4× ×Ｐ＝６０ ５ ２．６

/＝１．１５ＰＳ ｃｍ2

M/ N,C/ R,C/ Mホワイトメタル

5MPa負荷容量１

４気筒３点支持鍛造軸カム軸歯車駆動スラスト軸受はリア側で支持

1970 Ｔ－Ｕ型 78PS 141Ｋｇセリカ

カローラカリーナ

:Φ × ×Ｍ／Ｎ ６２ ２０．８ ２．０Φ × ×Ｃ／Ｒ： ５１ １９ １．５/ × ×Ｐ＝７８ ４ ４．８ １．８

/＝２．２６ＰＳ ｃｍ2

Ｍ／Ｎ，Ｃ／Ｒ- -Ｐｂ Ｓｎ Ｃｕ付

銅・鉛合金MPa負荷容量３０

Ｃ／Ｍホワイトメタル

４気筒５点支持ＤＣＩ軸カム軸チエン駆動スラスト軸受はセンターで支持

1980 ５ＡPS８５

６０００ＲＰＭ

１１６Ｋｇカリーナカローラコロナ

Φ × ×Ｍ／Ｎ： ５２ ２０ ２．０Φ × ×Ｃ／Ｒ： ４３ １７．１ １．５/ × ×Ｐ＝８５ ４ ４ １．７４

/＝３．０５ＰＳ ｃｍ2

Ｍ／Ｎ，Ｃ／Ｒ- -ＡＬ Ｓｎ Ｓｉ

MPa負荷容量３０

４気筒５点支持ＦＣＤ７０軸ＤＯＨＣ軸タイミングベルト駆動スラスト軸受はセンターで支持

1990 ５ＥPS１０５

６４００ＲＰＭ

１０７Ｋｇターセル

Ⅱカローラコルサ

Φ × ×Ｍ／Ｎ： ５４ １６ ２．０/ Φ × ×Ｃ Ｒ： ４６ １６ １．５

/ 4× ×Ｐ＝１０５ ４．３ １．４ ＝４．３６ＰＳ／ｃｍ2

Ｍ／Ｎ，Ｃ／Ｒ- -ＡＬ Ｓｎ Ｓｉ

5MPa負荷容量３

４気筒５点支持ＦＣＤ軸ＤＯＨＣ軸タイミングベルト駆動スラスト軸受はセンターで支持

50

100

150

200

1960 70 80 90 2000 年度

重量

ｋｇ

0

50

100

150

PS出

力

重量PS

0

2

4

6

1960 70 80 90 2000 年度

PS/c

m2

軸受

負荷

PS/ cm2

by K. Niwa

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Trends of Automotive Engines & Influences on Bearing

Needs Trend of Engines Influences on Bearing

・ Direct ignition & higher cylinder pressure (Gasoline)・ High pressure fuel jet & higher cylinder pressure (Diesel)

No.

・ Down-size, Thin wall, Light weight Materials (Al alloy)・ Reduction of Friction Loss・ Increase of Start–Stop Operation

・ Lower volume of Oil Pump・ EGR・ Direct ignition & higher cylinder pressure

・ Reduction of bearing slap noise

・ Higher Reliability・ Commoditizing

・ Higher Unit Load　→① Al-Sn-Si alloy, 　　 ② Microgrooved Bearing

・ Lower Rigidity of Housing

・ Narrow Width → Higher Unit Load・ Lower Viscosity Oils・ Excessive Wear④Eccentric grooved Bearing・ Higher Oil Temp.・ Higher Unit Load

・ Smaller Diametral Clearance②Microgrooved Bearing

・ Higher Durability・ Commoditizing, Lower cost

1

2

3

4

5

High performance

Improve of Fuel Consumption

Clean Exhaust Gas

Reduction of Noise & Vibration

Others longer life, cost reduction6

Reduction of Environmental Substances of Concerns

・ Less or Free of lead ・③ Lead Free Materials

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４　今後の課題と方向Influence on Bearings 　　年頃

・ higher unit load　→鉛青銅系ライニング、　　　鉛系オーバレイ

1970 年～　　 2000 年

1995 年～　　現在

1975 年～　　 2005 年

1995 年～　　現在

1990 年～　　 2000 年

・ マイクログルーブ軸受（ MGB ）

High performance

Improve of Fuel Consumption

Clean Exhaust Gas

Reduction of Noise & Vibration

Reduction of Environmental Substances of Concerns

Others -- longer life, cost reduction

Needs Trend of Engines

1

2

3

4

5

6

・ Direct ignition & higher cylinder pressure (Gasoline)・ High pressure fuel jet & higher cylinder pressure (Diesel)

・ EGR・ Direct ignition & higher cylinder pressure

・ Reduction of bearing slap noise

・ Higher Reliability・ Commoditizing

・ Less or Free of lead

・ Down-size, Thin wall, Light weight Materials (Al alloy)・ Reduction of Friction Loss・ Increase of Start–Stop Operation

・ Lower volume of oil pump

No.

・ Higher Durability, Commoditizing, Lower cost

・ Lower Rigidity of Housing

・ Narrow Width → Higher Unit Load・ Lower Viscosity Oils・ Excessive Wear

・ Higher Oil Temp.・ Higher Unit Load

・ Smaller Diametral Clearance

・ Lead Free Materials

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3.3.1 　従来（ Pb 含有）軸受の性能位置付け　

スポーツタイプガソリンエンジン

ディーゼルエンジン

一般ガソリン　エンジン

SA161SA151

LN750/HD150LN760/HD240

LN762

8 12 16

20

40

60

80

20周速　， m/s

100

最大

軸受

面圧

　，

MP

a

24

120

今後の開発エンジンの領域（予測）

コンロッド軸受最高出力時

【材料記号説明】　オーバレイ材／ライニング材

3.3 　鉛フリー軸受

Al-Sn-Si-Pb 合金

Pb 基ｵｰﾊﾞﾚｲ付き銅鉛合金or 鉛青銅

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・ Addition of Solid lubricantsGraphite(Gr)MoS2, WS2

PTFE Sulfide ： Cu2S ， AgS ・・・

・ Addition of Ag 〔 HS100 ， HS210 〕

・ Addition of Low Melting Point MetalBi ， Sn ， In

Conformability

・ Lower hardness　　　 addition of Soft components Gr ， MoS2 ， PTFE ・・

・ Surface Modification　　 Sn electroplating　① Solid Lubricant Coating 〔 RA500 〕　② Microgrooved Bearing

・ Hard Particle　　 Enlarged Si ， Fe-P ， AlN ・・・

Boundary Lubricity

Concept of Pb Free BearingConcept of Pb Free Bearing

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摺動メカニズム：　油中の S,O の存在と摩擦熱とによって、極表面に約 0.1～ 0.2μm の厚さで次の物質が形成される． (ESCA ， AES ， EPMA 分析結果 ) 　　　　　　　　

③-1　トライボケミカル反応の利用 -Ag の添加

SnAg

Cu

応力や摩擦熱

オイル中の　　 S ， O

表面への Sn,Ag の富化

Sn,Agを固溶した非平衡 Cu マトリックス

Cu2O ， SnO2

の薄い層

CuSO4

Sn リッチAg3Sn-Sn共晶

（ AgS,SnS等）部分的に数 μm 厚さの Cu2O ,CuSO4

表面

軸受

合金

Fig.3Smaller and stable friction coefficient ofSn-Agthin layer

Coefficient

of friction

00.2

0.4

0.6

Sliding distance (time) →30mm（91sec)

Sn-Agbulk

0.1mSn-Agon Cu-5Sn Cu-5Sn bulk

Fig.3Smaller and stable friction coefficient ofSn-Agthin layer

Coefficient

of friction

00.2

0.4

0.6

00.2

0.4

0.6

Sliding distance (time) →30mm（91sec)

Sn-Agbulk

0.1mSn-Agon Cu-5Sn Cu-5Sn bulk

出典：神谷荘司，名古屋大学学位論文　　　　（ 1999 ）

5Sn-1Ag thin layer

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【試験方法】試験機 ： 高面圧軸受試験機

軸受材質 ： SA162, RA530/SA250軸受寸法 ： 内径 φ42×幅 17mm給油温度 ： 140℃試験軸 ： S55C 焼入れ　　　　　　表面粗さ RzJIS 0.5μm 硬さ 500 - 600HV10

回転数[r/min]

軸受面圧　　 [MPa] 20

105

0 45 　 90 135 175 220 〔 min 〕

1300

45min 毎に10MPa ステップアップ

3040

50

0 45 　 90 135 175 220 〔 min 〕

混合潤滑領域の摩擦係数，焼付き面圧を確認

軸

供試軸受オイルバス

油圧ピストン

モーター

ひずみゲージ

荷重パターン試験機

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1750 　　 Half bearing (← Leonardo da Vinci at the Renaissance) 　～ 　 　　　 :replaceable in case of excessive wear 　　　　　　　　　　 1850 　　 Bearing Materials 　　　　　　　　　　　　　 : cast iron, bronze, brass, pewter (Alloy of tin, lead and zinc) 　　　　　　　　　

Industry RevolutionIndustry Revolution

Brass half bearing

Ref. : D ． Dowson, History of Tribology 2nd edition, Professional Engineering Pub. (1998) 201. 　

1.1 Short History

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Sn/Cu-6Sn-1Ag

Bi/Ag/Cu-10Sn-4Bi-Mo2C

Size ： - １ μm

Size ：１ - ５ μm

Dendrite

Granule

22HV

12HV

Bi:5μm

Ag:5μm

基材

Cross Overlay Overlay Crystal size Hardness -section surface fracture s.

5μm 5μm5μm

Fine

Bi

Ag

基材

基材

BP100X

CX4

裏金

PK1

2.3.5 Sn,Bi electroplating

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45

0

0.2

0.4

0.6

0.8

1

Conventional No.1 No.2Em

bedded

Rate

Engine : L4, 1.5LRotational Speed : 6400rpmOil Temp. : 120ºC

[ Test conditions ]

A : Crank pin lower side

B : Crankshaft bearing back side

125

130

135

140

145

150

Conventi

onal

No.

1

No.

2

No.

3

Tem

pera

ture

, º

C +0.8ºC +1.5ºC +1.4ºC

+2.1ºC +2.5ºC+1.2ºC

Eccentric

3.1.4 temperature increase and embeddability of Eccentric oil-grooved bearing

Embedded rate of foreign particleson connecting rod bearings