Hi-TINAL: Advanced High-Tin Aluminium Plain Bearing Alloys Produced by Intensive Melt Shearing Technology

Rolls Royce Goodrich Engine Control Systems Ltd. (Aero Engine Controls) is leading a project team which includes KC Engineering Ltd (KC) and the Brunel University Centre for Advanced Solidification Technology (BCAST), to develop and demonstration test an innovative high-Sn Al plain bearing alloy that will lead to replacement of hazardous lead-tin bronzes and whitemetals, reduce product manufacturing cost and extend service intervals. The selected project team members have the capability and skills to optimise the alloy composition and tribological properties for early application in high value product markets such as aerospace and oil & gas and longer term application in high volume markets such as automotive. The team will build on successful fundamental research carried out by BCAST using their innovative intensive melt shearing technology (MCAST) to generate well dispersed high-Sn Al microstructures at the laboratory scale. This capability will significantly reduce project risk going forwards. The project will demonstrate the applicability of this material to a range of full scale parts and optimise the process for reliable manufacture. Exploitation is aimed initially at aerospace fuel system and oil & gas industry related components to secure the market position and stimulate growth in market share of the end user partners. “Spill over” economic benefits will be available outside the consortium: (i) bearing manufacturers in other sectors; (ii) AEC and KC’s customers and other end users of bearings and sytems containing bearings; (iii) Al and master alloy raw materials suppliers through greater penetration into the bearings market.