Controlled-dispersion of solid lubricious particles in a metallic alloy matrix

A method of making a bearing wear surface for a compressor component, the method comprising:

• heating an admixture of a plurality of solid lubricant particles and a metal alloy material to melt the metal alloy material, wherein the molten metal alloy material has a first density and the plurality of solid lubricant particles have a second density, wherein a difference between the first density and the second density is greater than or equal to about 25% and the metal alloy material comprises a copper alloy and the plurality of solid lubricant particles is selected from the group consisting of:
• nickel-coated graphite particles, copper-coated graphite particles, zinc-coated graphite particles, uncoated graphite particles, and combinations thereof,
• mixing and cooling the admixture, so that the molten metal alloy material cools to form a semi-solid slurry admixture;
• introducing the semi-solid admixture into a die;
• and
• solidifying the semi-solid slurry admixture to form a cast solid component comprising a bulk region formed of a metal alloy material comprising a copper alloy and at least one bearing wear surface having the plurality of the solid lubricant particles homogeneously distributed within a matrix of the metal alloy material, the cast solid having less than or equal to about 1% by volume porosity,
• wherein the plurality of the solid lubricant particles is present along at least one bearing wear surface of the solid component at greater than or equal to about 10 volume % to less than or equal to about 30 volume % of a total combined volume of the plurality of the solid lubricant particles and the matrix, wherein the compressor component is substantially lead-free.