Abstract: A compressor may include a non-orbiting scroll, an orbiting scroll, a driveshaft and an Oldham coupling. The orbiting scroll meshingly engages the non-orbiting scroll. The driveshaft includes a crankpin engaging the orbiting scroll and driving the orbiting scroll in an orbital path relative to the non-orbiting scroll. The Oldham coupling may include an annular body and a plurality of first keys extending from the annular body and slidably received in slots formed in the orbiting scroll. Each of the first keys may include a first post and a first cap attached to the first post. The first posts may be integrally formed with the annular body from a first material. The first caps may be formed from a second material.

Abstract: Methods for making a tribological bearing wear surface for a compressor component are provided. Such methods involve semi-solid metal casting, where an admixture of solid lubricant particles and a metal alloy material is heated to melt the metal alloy material, while the lubricant particles remain in a solid phase. The alloy material and solid lubricant have substantially different densities. The metal alloy material may be a copper, iron, or aluminum alloy, for example. The method further comprises mixing and cooling the admixture to form a semi-solid slurry admixture. Next, the method comprises introducing the semi-solid slurry admixture into a die. Finally, the semi-solid slurry admixture in the die is solidified to form a solid component having the solid lubricant particles homogenously distributed within a metal alloy material matrix, thus forming a metal matrix composite. Compressor components made from such methods are also provided.

Abstract: A compressor may include a non-orbiting scroll, an orbiting scroll, a driveshaft and an Oldham coupling. The orbiting scroll meshingly engages the non-orbiting scroll. The driveshaft includes a crankpin engaging the orbiting scroll and driving the orbiting scroll in an orbital path relative to the non-orbiting scroll. The Oldham coupling may include an annular body and a plurality of first keys extending from the annular body and slidably received in slots formed in the orbiting scroll. Each of the first keys may include a first post and a first cap covering at least a portion of the first post. The first posts may be integrally formed with the annular body from a first material. The first caps may be attached to the first posts and formed from a second material.

Abstract: A compressor may include a shell, a crankshaft, a piston and a connecting rod. The shell may define a cylinder. The crankshaft is supported for rotation relative to the shell. The piston reciprocates within the cylinder in response to rotation of the crankshaft. The piston and the cylinder define a compression chamber therebetween. The connecting rod includes a first bushing rotatably coupled to the piston and a second bushing rotatably coupled to the crankshaft. The second bushing may include a driving surface contacting the crankshaft and having a recess formed therein. The recess receives an insert.

Abstract: Methods of forming scroll compressor components are provided. The methods include forming at least one component of a scroll member from a powder metallurgy technique and joining the component with another distinct component via a sinter-brazing process. For example, a baseplate having a spiral scroll involute is joined to a hub via a joint interface having brazing material to form a braze joint with superior quality. At least one component is formed from a powder metal material including carbon and at least one species that reacts with or binds carbon to prevent migration during brazing of the sinter-brazing heat process. Optionally, during the powder metallurgy process, an alloy with a lower concentration of carbon is selected, which may be incorporated into a crystal structure with the species that prevents carbon migration.