The white metal, or Babbitt, bearing metal, based on lead or tin, has excellent frictional properties. It also possesses a number of other important properties such as embeddabitity, conformability and corrosion resistance. However, it is mechanically weak. Tin-lead alloys are most commonly used for solders and bearings. Solder preforms are used to joint various parts of an electronic package. Because the thermal expansion coefficient of a solder is in general much higher than that of a substrate, the solder joint suffers from poor resistance to thermal fatigue. Thus, there is a need for a solder with a low thermal expansion. On the other hand, if tin-lead alloys can be made stronger, they can carry greater bearing loads and hence offer the possibility of reduction in overall bearing size for a given application. Composite materials can be tailored to exhibit a chosen thermal expansion coefficient, as the filler species and the filler volume fraction can be suitably chosen. For a low thermal expansion composite, the filler must have a low thermal expansion coefficient. Moreover, the filler should be a good electrical conductor because the soldered joint then serves as a good electrical connection as well as mechanical connection. It is also required to be a good thermal conductor to enable heat dissipation from the electronic package. In addition, the filler should have good mechanical properties in order to strengthen the tin-lead alloy. One of the suggested means of strengthening bearings involves the incorporation of carbon fibres, thus using the fibres as a reinforceing agent and possibly also as a lubricating agent by a virtue of its graphite nature. Carbon fibres also have near-zero thermal expansion coefficient. Furthermore, carbon fibres are widely available in continuous form, which makes them more effective in lowering the thermal expansion coefficient of the composite and which prevents fibre distribution from becoming nonuniform after remelting and solidification [2]. Carbon fibre reinforced tin-lead alloys have been fabricated by liquid metal infiltration [1, 2] and by investment casting for fundamental process studies [3, 4]. It is well known that carbon fibres are not wetted by liquid lead or tin. In order to produce good wetting and prevent chemical reaction between carbon fibres and metal matrix during synthesis of composites, fibres have often been coated with refractory or metal materials [4-7]. In the previous studies [1-4], carbon fibres were electroplated with copper or nickel in order to ensure good wetting of the fibres by the alloy, but the weak bonding
Read full abstract