Influence of different pore-forming agents on the properties of CuSn10 alloy prepared by powder metallurgy

Purpose This study aims to examine the effects of different types of pore-forming agents (PFAs) on the properties of CuSn10 alloy prepared by powder metallurgy. Design/methodology/approach CuSn10 powder was mixed with different PFAs to prepare copper-based materials by powder metallurgy. The microstructures were characterized by scanning electron microscopy. Crushing strength and impact toughness were evaluated using a universal electronic testing machine and a 300 J pendulum impact tester, respectively; antifriction and wear resistance were evaluated using a ball-on-disk tribometer. Findings Organic PFAs (starch, fiber and polymethyl methacrylate) formed pores through space occupation followed by thermal decomposition or carbonization, whereas inorganic NaCl formed pores through space occupation and subsequent dissolution removal. Fibers produced narrow, interconnected pores that increased porosity, pore connectivity, oil-storage capacity and oil-release, whereas the NaCl-derived pores showed the poorest connectivity. Introducing PFAs reduced the mechanical properties of the materials but improved their antifriction performance and wear resistance. The fiber-containing material showed the largest decreases in impact toughness and crushing strength (19.9% and 17.5%, respectively) and the best antifriction performance, with a 65.5% reduction in the friction coefficient relative to the material without a PFA. Materials containing starch PFAs showed the best overall mechanical and wear resistance, with an 83.2% reduction in wear rate. Originality/value This study clarifies how PFA chemistry and morphology affect pore formation and, in turn, the mechanical properties, oil-storage and oil-release behavior, antifriction performance and wear resistance of CuSn10 materials. The findings provide guidance for the engineering design of porous materials produced by powder metallurgy. Peer review The peer review history for this article is available at: Link to the cited article