Method of making non-galling parts using amorphous metal surfaces

Abstract

Provided is a method for increasing anti-galling of parts using a coating material comprising an amorphous alloy. The parts may be a vehicle or machine component, for example, that are subject to frictional and sliding forces. The disclosed coating reduces galling and friction between surfaces, and increases the lift of such parts.

What is claimed is: 
     
         1 . A method of increasing galling resistance of a substrate comprising coating a material over at least a portion of a surface of a substrate, wherein the coating material comprises an amorphous alloy. 
     
     
         2 . The method according to  claim 1 , wherein the coating material withstands testing according to the ASTM G 98-02 standard. 
     
     
         3 . The method according to  claim 1 , wherein the coating is performed using a thermal spray process. 
     
     
         4 . The method according to  claim 1 , wherein the coating comprises utilizing at least one of: a flame spray, electric arc wire spray, plasma spray, high velocity oxy-fuel spray, high-velocity air-fuel spray, cold spray, welding, or a cladding deposition process. 
     
     
         5 . The method according to  claim 1 , wherein the substrate is a vehicle component or a machine component. 
     
     
         6 . The method according to  claim 1 , wherein the substrate is at least a part of a piston ring, a synchronizer ring, a synchronizing assembly, a shift fork, a differential shaft, a differential pin, a transaxle assembly, a differential assembly, a fuel injector, a cam follower, a gear, a valve, a pump component, and a lathe bedway. 
     
     
         7 . The method according to  claim 1 , wherein the material is applied in the form of a layer over the surface of the substrate, and wherein the layer has a thickness of between about 50 microns and about 1000 microns. 
     
     
         8 . The method according to  claim 1 , wherein the material has a friction coefficient of about 0.1 or less. 
     
     
         9 . The method according to  claim 1 , wherein the material has a wear resistance characterized by a volume loss of less than about 10 mm 3 . 
     
     
         10 . The method according to  claim 1 , wherein the material is resistant to temperature induced degradation at temperatures up to about 1000° C. 
     
     
         11 . The method according to  claim 1 , wherein the material has a hardness of between about 600 HV and about 1500 HV. 
     
     
         12 . The method according to  claim 1 , wherein the material has a hardness of greater than about 1000 HV and a crystallization temperature of greater than about 600° C. 
     
     
         13 . The method according to  claim 1 , wherein the substrate exhibits improved galling resistance when compared to another component in the absence of the coating material. 
     
     
         14 . The method according to  claim 1 , wherein the substrate exhibits improved sliding properties when compared to another component in the absence of the coating material. 
     
     
         15 . An article comprising:
 a substrate, and   a coating material disposed over at least a portion of a surface of the substrate;   wherein the coating material comprises an amorphous alloy.   
     
     
         16 . The article according to  claim 15 , wherein the coating material withstands testing according to the ASTM G 98-02 standard. 
     
     
         17 . The article according to  claim 15 , wherein the substrate is a vehicle or machine component. 
     
     
         18 . The article according to  claim 15 , wherein the substrate is at least a part of a piston ring, a synchronizer ring, a synchronizing assembly, a shift fork, a differential shaft, a differential pin, a transaxle assembly, a differential assembly, a fuel injector, a cam follower, a gear, a valve, a pump component, and a lathe bedway. 
     
     
         19 . The article according to  claim 15 , wherein the coating material is in the form of a layer over the substrate, and wherein the layer has a thickness of between about 50 microns and about 1000 microns. 
     
     
         20 . The article according to  claim 15 , wherein the coating material has a friction coefficient of about 0.1 or less. 
     
     
         21 . The article according to  claim 15 , wherein the coating material has a wear resistance characterized by a volume loss of less than about 10 mm 3 . 
     
     
         22 . The article according to  claim 15 , wherein the coating material is resistant to temperature induced degradation at temperatures up to about 1000° C. 
     
     
         23 . The article according to  claim 15 , wherein the coating material has a hardness of between about 600 HV and about 1500 HV. 
     
     
         24 . The article according to  claim 15 , wherein the coating material has a hardness of greater than about 1000 HV and a crystallization temperature of greater than about 600° C. 
     
     
         25 . The article according to  claim 15 , wherein the article exhibits improved galling resistance when compared to another component in the absence of the coating material. 
     
     
         26 . The article according to  claim 15 , wherein the article exhibits improved sliding properties when compared to another component in the absence of the coating material.