The friction and wear performance of a Cu-4Al top foil coating has
been investigated in Generation I foil air bearings. The copper
alloy was applied by a novel deposition technique (ion diffusion)
and the journal was coated with PS304, a plasma spray deposited
high temperature composite solid lubricant coating. The ion
diffusion coating process deposits a desirable smooth layer
compared to other methods like cathodic arc deposition. The
tribological performance of bearings with and without Cu-4Al foil
coatings were evaluated through start-stop tests on an air bearing
test rig at 25 and 650 C. The results indicate that the Cu-4Al
assists during the initial break-in period, gives more stable
friction performance with respect to temperature, and appears to
prevent top foil wear at high temperature. The measured load
capacity coefficient was 0.5, which was comparable to earlier
testing of more advanced design Generation III bearings coated with
standard cathodic arc deposited Cu-4Al. However, further studies
are needed to determine if deeper penetration of the copper alloy
into the foil would help make the transition in friction behavior
from contact with the Cu-4Al coated foil to contact with the base
foil material more gradual. Also, future work is recommended to
assess the performance of ion diffusion coatings with different
Cu-based alloy compositions and to investigate the effect the
coating has on the elastic modulus of the foil material.
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