Abstract Sliding bearings have to fulfil various requirements depending on the operating conditions. Conventional sliding bearings, however, cannot be used for critical operating conditions such as frequent acceleration and shut-down procedures or they require the use of complex manufacturing processes and cost-intensive material solutions. For this reason, complex multilayer systems or rolling bearings are currently used for frequent start-up cycles and low relative velocities. New material systems and manufacturing processes are of particular interest in order to operate sliding bearings cost-effectively and reliably even under these increased requirements. Within the scope of this study, new material concepts are developed by thermal spraying. Thermal spraying allows the production of innovative material combinations, which cannot be produced by melting metallurgy. In addition, coatings can be applied by thermal spraying on a wide variety of geometries directly on the bearing support structure, thus achieving increased freedom of design and additional cost savings compared to conventional processes. The coating concepts are based on a cobalt or bronze matrix into which friction-reducing solid lubricants can be integrated during the coating process. One particular goal of the coating concepts is to improve the operating properties under critical conditions, such as low relative velocities and high loads. Therefore, the developed coatings are tested on a modified ring-on-disc tribometer and are compared to a reference sliding bearing material produced by conventional casting. To verify the coating capability, the most promising coating is investigated on a full-scale main bearing test bench of a wind turbine. For the first time, a thermally sprayed coating and a new conical sliding bearing design are evaluated as a substitution for currently used rolling bearings as main bearings in wind turbines. Hereby, it is demonstrated whether these new coating concepts can meet the requirements of this highly stressed bearing position.

中文翻译：

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用于高应力滑动轴承的热喷涂涂层

摘要 滑动轴承必须根据运行条件满足各种要求。然而，传统的滑动轴承不能用于关键的操作条件，例如频繁的加速和停机程序，或者它们需要使用复杂的制造工艺和成本密集的材料解决方案。出于这个原因，复杂的多层系统或滚动轴承目前用于频繁的启动周期和低相对速度。即使在这些增加的要求下，为了经济高效且可靠地运行滑动轴承，新材料系统和制造工艺尤其令人感兴趣。在本研究的范围内，通过热喷涂开发了新的材料概念。热喷涂允许生产创新的材料组合，不能用熔炼冶金法生产。此外，涂层可以通过热喷涂直接喷涂在轴承支撑结构上的各种几何形状上，从而与传统工艺相比，实现更大的设计自由度和额外的成本节约。涂层概念基于钴或青铜基体，在涂层过程中可以将减少摩擦的固体润滑剂集成到该基体中。涂层概念的一个特定目标是改善临界条件下的操作性能，例如低相对速度和高负载。因此，开发的涂层在改进的环盘摩擦计上进行测试，并与通过传统铸造生产的参考滑动轴承材料进行比较。为了验证涂层能力，在风力涡轮机的全尺寸主轴承试验台上研究了最有前途的涂层。首次评估了热喷涂涂层和新型锥形滑动轴承设计，以替代目前用作风力涡轮机主轴承的滚动轴承。从而证明这些新的涂层概念是否能够满足这种高应力轴承位置的要求。