Thermoset polymer/solid lubricant coating system

A method of making anti-friction coated cylinder walls subject to sliding loads, comprising:

• (a) providing a light metal-based cylinder surface;
• (b) exposing nonoxidized metal of said cylinder surface;
• (c) applying a high elastic modulus load-supporting metal layer, the metal layer containing one or more of the solid film lubricant, onto the light metal cylinder surface;
• and
• (d) distributing simultaneously a solvent-based solid film lubricant mixture and thermoset polymer onto at least portions of said metal layer at about room temperature to form a coating of desired thickness, the solid lubricant mixture comprising at least two elements selected from the group consisting of graphite, MoS.sub.2, and BN, and the polymer adhering said mixture to said layer upon flowing thereagainst.

A method of making anti-friction coated light metal cylinder bore walls subject to sliding loads and wet lubrication, comprising:

• (a) exposing fresh metal of said walls;
• (b) modifying said fresh metal to provide a load supporting capability;
• (c) coating said modified fresh metal with a solid lubricant containing mixture, said mixture comprising an emulsion of solid lubricant particles and thermoset polymer, said solid lubricants being at least two elements selected from graphite, MoS.sub.2, and BN;
• and
• (d) curing said coating.

A cylinder block for an internal combustion engine having one or more anti-friction coated cylinder bores, comprising:

• (a) a cast aluminum-based cylinder block having at least one cylinder bore surface;
• (b) a hard load-supporting face-on said bore surface;
• and
• (c) a coating on said face comprised of an oil-attracting solid lubricant mixture and a thermoset polymer that supports loads of at least 10 psi at temperatures of 600.degree.-800.degree. F. and is stable at such temperatures, the mixture having at least two elements selected from the group consisting of graphite, molybdenum disulfide, and boron nitride, the thermoset polymer having inherently high hydrocarbon chemical attraction and being adhereable to said face upon flowing thereagainst with temperature stability at 600.degree.-800.degree. F.