Metal-Polymer Bearings
Low Friction, Energy Efficiency: Enhanced energy performance thanks to the low-friction properties of the PTFE-enriched overlay.
Self-lubricating rolled bearings
Self-lubricating rolled bearings, particularly composite bushings with a three-layer dry bushing design, offer advanced solutions for reducing friction and enhancing performance across various applications. These innovative bearings utilize a combination of materials, including polymer coatings, metal-polymer composites, and fiber-reinforced composites, to achieve optimal durability and efficiency.
Structural Composition and Properties
The SF-1 metal self-lubricating rolled bearing is constructed from high-quality low-carbon steel as the substrate. It features a sintered layer of spherical porous copper powder in the middle and a surface layer made from PTFE-based wear-resistant lubricating material. This design provides excellent mechanical properties and bearing capacity. The copper powder layer effectively dissipates heat generated during operation while enhancing the bonding strength between the plastic layer and the substrate. The PTFE material is specifically engineered for dry friction applications, with various formulations developed to meet lubrication, friction coefficient, and durability requirements. PTFE metal composites deliver high performance across a broad spectrum of loads, speeds, and temperatures, functioning effectively with or without external lubrication.
Key Components:
- PTFE Layer: Provides low friction and wear resistance.
- Spherical Bronze Powder Layer: Enhances thermal conductivity and bonding strength.
- Steel Backing: Offers structural integrity and load-bearing capacity.
- Copper/Tin Layer: Supports lubrication and heat transfer.
Advantages of Composite Bearings
Composite bearings are designed to minimize friction while providing self-lubricating capabilities. Their layered structure allows each component to contribute to specific performance aspects:
- Reduced Maintenance: The self-lubricating feature significantly decreases the need for regular maintenance, which can lead to lower operational costs.
- High Load Capacity: These bearings can handle heavy loads due to their robust construction.
- Chemical Resistance: Composite materials resist degradation from harsh chemicals, making them suitable for various industrial environments.
- Versatility: They are adaptable for different applications, including automotive, construction, and heavy machinery.
Applications
Self-lubricating composite bearings are particularly effective in scenarios involving:
- High Loads: Their design accommodates significant compression and shock without deformation.
- Extreme Temperatures: They perform well in both cryogenic conditions and elevated temperatures.
- Low-Friction Requirements: With coefficients of friction as low as 0.05 in dry applications, they are ideal for reducing wear on mating surfaces.
In summary, self-lubricating rolled bearings with composite bushings represent a significant advancement in bearing technology. Their unique structural properties and benefits make them an excellent choice for enhancing operational performance while minimizing maintenance needs across diverse applications！
The excellent low friction and high wear resistance performance of metal-polymer bearings make them ideal for hundreds of applications in numerous and diverse industries. Depending upon application requirements, metal-polymer composite bearings can be produced in straight bushing and flanged bushing, thrust washer and custom sizes.
Metal-Polymer Bearings
High Wear Resistance with Low Friction
The specific type of loading applied to a bearing determines the appropriate shape, which can be selected from the following options:
Experience the Advantage
- Extended Service Life: Increased longevity from the high-wear-resistant bronze layer and superior overlay resistance against fatigue loading, cavitation erosion, and edge loading.
- Reduced Noise
- Eliminates metal-to-metal contact between the bearing and the shaft, reducing noise during operation.
- Efficient Operation
Reduced/Zero Maintenance
- Self-lubricating bearings that can operate dry, eliminating the need for grease. The overlay’s indents serve as grease reservoirs, further reducing maintenance needs.
- Increased Durability and Reliability
- Prevents shaft and bearing seizure under boundary lubrication conditions and frequent start/stop operations.
- Compact, Lightweight Design
- Achieved through thin-wall bearing construction for a space-saving solution.
- Improved operational efficiency with a machinable overlay, allowing for reduced clearances and perfect bearing geometry.
Metal-Polymer Materials
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Metal-Polymer bearings offer exceptional anti-friction and wear-resistant properties, allowing them to operate both dry or with external lubrication. Their unique composite structure ensures superior performance across a wide range of applications.
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We are committed to driving innovation in tribological bearings by continuously enhancing wear resistance and reducing friction. Recent advancements in tribological properties are enabling us to tackle new challenges and transform component design and manufacturing. Metal-Polymer solutions are highly versatile, ideal for hundreds of applications across various global industries. These materials can be easily customized to meet specific customer requirements, including grooves and holes for lubrication or punched and stamped shapes.
Metal Composite Self-Lubricating Bearing
The SF-1 self-lubricating bearing features a high-quality low-carbon steel substrate, with a sintered spherical porous copper powder layer at its core. The surface is coated with a PTFE-based wear-resistant lubricating material, which serves as the bearing’s working layer. This advanced composite construction provides exceptional mechanical bearing capacity. The porous copper layer efficiently dissipates heat generated during operation while enhancing the bond strength between the plastic layer and the substrate.
Designed for dry friction applications, PTFE is used in various formulations tailored to meet specific requirements for lubrication, coefficient of friction, and durability. VIIPLUS’s PTFE metal composites deliver optimal performance across a broad range of loads, speeds, and temperatures, both with and without external lubrication.
Metallographic pictures
Note: The product can also choose different base materials according to different working conditions, such as: bronze substrate (SF-1B), stainless steel substrate (SF-1S), and lead-free (SF-1W) and other formula products.
1.PTFE
2. Spherical bronze powder
3. steel back
4.Copper/Tin Layer
Wear Resistance of SF-1 Bearings
SF-1 bearings offer exceptional wear resistance, largely due to the unique molecular structure of PTFE. The wear process of SF-1 can be divided into three distinct stages, each with its own corresponding friction characteristics.
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“Run-in” Stage: During this phase, the PTFE mixture on the surface layer transfers to the mating surface, filling in any surface pits and forming a transfer film. As a result, the friction coefficient is higher, and the material experiences faster wear. This is represented by curve I in the figure.
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“Stable” Wear Stage: After the run-in period, the friction transitions to the interaction between PTFE and the mating surface. The friction coefficient becomes low and stable, and the wear rate of the material is reduced to a steady, minimal level. This is shown in zone II of the figure.
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“Sharp” Wear Phase: When the PTFE lubricant in the porous layer is depleted, insufficient lubricant is available between the friction interfaces. This results in poor lubrication, a rapid increase in friction coefficient, and a significant acceleration of the wear rate. The material’s lifespan approaches its end when approximately 70% of the bronze substrate is exposed, as shown in curve III.
Key Factors Affecting Service Life
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PV Value
The PV (Pressure x Velocity) value is a critical factor in determining the wear life of SF-1 bearings. To extend service life, the PV value must be kept within acceptable limits. -
Ambient Temperature
Higher ambient temperatures reduce the lifespan of SF-1 bearings. It is essential to consider temperature conditions when assessing bearing longevity. -
Material Pairing
The bearing’s service life can be significantly improved when paired with alloy steel or hard chrome-plated shafts. Surface roughness should ideally fall within the range of Ra = 0.4–0.63 to optimize performance and lifespan.
Applications
SF-1 bearings are suitable for a wide range of applications across various industries:
- Agricultural Machinery: Tractors, combine harvesters, crop sprayers, bulldozers, graders, etc.
- Automotive Industry: Power steering pumps, steering gear thrust pads, disc brakes, shock absorbers, door hinges, wipers, chair adjusters, air valves, solenoid valves, etc.
- Office and Business Machinery: Copiers, fax machines, printers, mail processors, etc.
- Hydraulic Components and Valves: Gear pumps, plunger pumps, vane pumps, ball valves, butterfly valves, air cylinders, oil cylinders, and other hydraulic components.
- Household Appliances: Refrigerators, air conditioners, vacuum cleaners, sewing machines, washing machines, microwave ovens, and fitness equipment.
- Other Machinery: Logistics machinery, packaging machinery, textile machinery, port machinery, mining machinery, forest machinery, and various types of construction machinery.
In addition to the standard products listed in the catalogue, non-standard products can also be tailored or ordered according to customer specifications.
