Thermal spray material comprising Al-Si alloy powder and a structure having a coating of the same

A method of making a structure having a sliding surface of a sliding member coated with a thermal spray material, comprising:

• preparing an AlSi alloy powder containing 12-30 weight percent Si, at least one element selected from the group consisting of 0.5-5.0 weight percent Cu and 0.2-3.0 weight percent Mg, 1-15 weight percent of at least one element selected from the group consisting of Fe, Mn, and Ni, and the material balance being Al;
• preparing a cast iron powder containing 2-4 weight percent C, not more than 0.3 weight percent Si, 0.5-3.0 weight percent P, and the material balance being Fe;
• mixing 5-30 weight percent of said AlSi alloy powder with 95-70 weight percent of said cast iron powder to obtain a thermal spray composition;
• and
• applying said thermal spray composition onto said sliding surface.

A structure having on a sliding surface of a sliding member comprising:

• a coating to coat said sliding surface;
• said coating containing 5-30 weight percent of an AlSi alloy powder and 95-70 weight percent of a cast iron powder;
• said AlSi alloy powder containing 12-30 weight percent Si, at least one element selected from the group consisting of 0.5-5.0 weight percent Cu and 0.2-3.0 weight percent Mg, 1-15 weight percent of at least one element selected from the group consisting of Fe, Mn, and Ni, and the material balance being Al;
• and
• said cast iron powder containing 2-4 weight percent C, not more than 0.3 weight percent Si, 0.5-3.0 weight percent P, and the material balance being Fe.