Aluminum thrust washer

• US 6,511,226 B2
• Filed: 09/04/2001
• Issued: 01/28/2003
• Est. Priority Date: 09/05/2000
• Status: Expired due to Fees

• Current Assignee: Federal-Mogul Worldwide Incorporated (Apollo Global Management, Inc.)
• Original Assignee: Federal-Mogul Worldwide Incorporated (Apollo Global Management, Inc.)
• Inventors: Thompson, Ronald Joseph, Whitney, Warren J.
• Primary Examiner(s): Hannon, Thomas R.
• Application Number:
  US09/945,938
• Publication Number:
  US 20020034349A1
• Time in Patent Office: 511 Days
• Field of Search: 384/123, 384/121, 384/294, 384/368, 384/420, 384/912, 384/913
• US Class Current: 384/420
• CPC Class Codes: F05C 2201/021 Aluminium
• CPC Class Codes: F16C 17/04 for axial load only
• CPC Class Codes: F16C 17/047 with fixed wedges to generate hydrodynamic pressure
• CPC Class Codes: F16C 2204/20 Alloys based on aluminium
• CPC Class Codes: F16C 33/1075 Wedges, e.g. ramps or lobes, for generating pressure
• CPC Class Codes: F16C 33/12 Structural composition; Use of special materials or surface treatments, e.g. for rust-proofing
• CPC Class Codes: F16C 9/02 Crankshaft bearings
• CPC Class Codes: Y10S 384/913 Metallic compounds

Abstract

An aluminum thrust washer that has a wrought aluminum matrix that includes from 2 to 20 weight percent silicon, 0.1 to 4 weight percent of copper, with the remainder pure aluminum. The aluminum thrust washer is formed of a mono-metal structure without a backing layer. The wrought aluminum matrix has mechanical properties such that the aluminum matrix wears away, leaving silicon particles exposed at a thrust face of the washer, such that the density of silicon particles is continually increasing as the thrust washer is utilized.

Claims

1. An aluminum thrust washer comprising:

a wrought aluminum matrix comprising;

2 to 20 percent by weight silicon;

0.1 to 4 percent by weight copper;

with the remainder aluminum;

said aluminum thrust washer being formed of a mono-metal without a backing layer.

2. The aluminum thrust washer of claim 1 wherein said aluminum matrix comprises 9.5 to 11.5 percent silicon, 0.75 to 1.25 weight percent copper, with the remainder aluminum.

3. The aluminum thrust washer of claim 1 wherein said aluminum matrix has silicon particles dispersed therein such that there are at least four silicon particles greater than 5 micrometers in size when counted in an area of 0.04 mm².

4. The aluminum thrust washer of claim 3 wherein said silicon particles have a maximum size of 15 micrometers.

5. The aluminum thrust washer of claim 1 wherein said aluminum matrix material wears away, leaving silicon particles exposed at a thrust face;

thereby, continually increasing the density of silicon particles at said thrust face as said aluminum thrust washer is used.

6. The aluminum thrust washer of claim 1 wherein said aluminum matrix material further includes from 0 to 5 weight percent of one or more elements selected from the group consisting of:

tin, lead, chromium, vanadium, manganese, magnesium.

7. The aluminum thrust washer of claim 1 wherein said aluminum thrust washer is formed by casting said aluminum matrix and then subsequently heat treating and cold rolling said aluminum matrix to obtain an alloy strip having a desired silicon particle dispersion and thereafter pressing said alloy strip to form said aluminum thrust washer.

8. The aluminum thrust washer of claim 1 wherein said aluminum matrix has sufficient strength to allow for a mono-metal structure without a backing and wherein said matrix is soft enough such that said aluminum matrix material wears away, leaving silicon particles exposed at a thrust face of said aluminum thrust washer as said thrust washer is used.

9. The aluminum thrust washer of claim 1 wherein said aluminum matrix has a hardness of from 45 to 65 Vickers.

10. The aluminum thrust washer of claim 1 wherein said aluminum thrust washer includes hydrodynamic features formed thereon.

11. The aluminum thrust washer of claim 1 wherein said aluminum thrust washer includes oil grooves formed thereon.

12. An aluminum thrust washer comprising:

a wrought aluminum matrix comprising;

2 to 20 percent by weight silicon;

0.1 to 4 percent by weight copper;

with the remainder aluminum;

said aluminum thrust washer being formed of a mono-metal without a backing layer and wherein said aluminum matrix has silicon particles dispersed therein such that there are at least four silicon particles greater than 5 micrometers in size when counted in an area of 0.04 mm².

13. An aluminum thrust washer comprising:

a wrought aluminum matrix comprising;

2 to 20 percent by weight silicon;

0.1 to 4 percent by weight copper;

with the remainder aluminum;

said aluminum thrust washer being formed of a mono-metal without a backing layer and wherein said aluminum matrix has sufficient strength to allow for a mono-metal structure without a backing and wherein said matrix is soft enough such that said aluminum matrix material wears away, leaving silicon particles exposed at a thrust face of said aluminum thrust washer, as said thrust washer is used.