Sealing ring

Abstract

A nickel-based alloy for forming a sealing ring (224) is disclosed. Such a seal ring (224) may be static or rotating in use, and may be used in a variety of applications, such as in a wheel assembly (108) for a machine (100). Using this alloy, a seal ring can be manufactured using a centrifugal casting process. The disclosed alloys include a chromium content greater than at least 13.5 wt%, a boron content less than 3 wt%, a carbon content less than 2 wt%, and a nickel content greater than 70 wt%. The nickel alloy may have a carbon plus boron atom content divided by a chromium atom content of less than 1.1. This alloy allows for rapid cooling of centrifugal casting while maintaining grain morphology suitable for relatively low leakage and relatively high durability. The sealing ring (224) is formed by centrifugal casting when the alloy is formulated.

Description

Technical Field

[0001] The present invention relates to a sealing ring for a machine, and more particularly to a sealing ring that can be centrifugally cast to meet sealing performance standards. Background Art

[0002] Machines, such as mining trucks, loaders, bulldozers, compactors, or other construction or mining equipment, are often used in construction, building, mining, and other activities. For example, mining trucks are often used to transport mined materials from a mining site. These machines typically have one or more sealing assemblies, such as sealing assemblies associated with their wheels. These sealing assemblies are capable of retaining lubricant within a sealed cavity and excluding impurities from the ball bearing surfaces and / or between relatively moving parts disposed within the sealed cavity. The sealing assembly may include a face seal, wherein the seal is formed by mating surfaces of relatively rotating sealing rings, the sealing rings being made of a relatively hard material. The sealing rings within the sealing assembly allow lubrication of moving parts, such as those associated with the wheels of the machine.

[0003] While sealing rings and / or sealing assemblies play an important role in the operation of machines and other equipment, surface roughness and / or inappropriate grain microstructure of the sealing rings may result in suboptimal operation. For example, if the sealing ring has too much and / or too little surface roughness, the sealing ring may leak oil contained in the bearing cavity. In addition, if the sealing ring lacks a preferred crystal structure and / or morphology, the sealing ring may wear excessively. Furthermore, since the sealing ring is a consumable part, it is expected that the sealing ring is relatively wear-resistant and relatively inexpensive. Therefore, it is expected that the ring seals are manufactured using low-cost methods, such as centrifugal casting. Not all alloy compositions, such as conventional alloy compositions, are compatible with low-cost methods for manufacturing sealing rings so that the sealing rings operate properly (e.g., have low leakage, have high durability, etc.).

[0004] A mechanism for forming an alloy that can be used to form a seal is described in U.S. Patent No. 9,222,154 (hereinafter referred to as the "'154 patent"). The '154 patent describes a white cast iron alloy having high wear resistance. The white cast iron alloy can be used to form any type of component using sand casting. However, the alloy and method described in the '154 patent are for sand casting and are not advantageous for low-cost methods of forming seal rings, such as centrifugal casting. Therefore, using the alloy of the '154 patent for centrifugally cast seal rings may result in less than ideal operation of the seal ring or may require expensive post-casting processing of the seal ring, thereby eliminating the advantages of the low-cost casting method.

[0005] Examples of the present invention are directed to overcoming one or more of the above-mentioned disadvantages. Summary of the Invention

[0006] In one aspect of the present invention, a sealing ring includes a body having a generally annular shape and a sealing end and a sealing flange disposed at the sealing end of the body, the sealing flange surrounding the body. Furthermore, the sealing ring is made of an alloy comprising less than 4 wt% silicon (Si), greater than 13.5 wt% chromium (Cr), less than 3 wt% boron (B), less than 2 wt% carbon (C), and greater than 70 wt% nickel (Ni).

[0007] In another aspect of the present invention, an alloy for a sealing ring includes 2 wt % to 5 wt % iron (Fe), greater than 13.5 wt % chromium, greater than 65 wt % nickel (Ni), 1 wt % to 3 wt % boron (B), and less than 2 wt % carbon (C).

[0008] In yet another aspect of the present invention, a method of manufacturing a seal ring includes: forming a rough seal ring from an alloy using centrifugal casting; and machining the rough seal ring to at least one predetermined tolerance. The alloy includes less than 4 wt% silicon (Si), greater than 13.5 wt% chromium (Cr), less than 3 wt% boron (B), less than 2 wt% carbon (C), and greater than 70 wt% nickel (Ni). BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a schematic diagram of an example machine having a sealing ring according to an example of the present invention.

[0010] Figure 2 According to an example of the present invention, Figure 1 A schematic diagram of the environment of the wheel assembly of the machine is depicted.

[0011] Figure 3 According to an example of the present invention Figure 1 Schematic diagram of a top view of the sealing ring of the machine depicted.

[0012] Figure 4 According to an example of the present invention Figure 3 Schematic diagram of a cross-sectional view of a sealing ring.

[0013] Figure 5 is a diagram illustrating an example of a method for manufacturing a Figure 3 A flow chart of an example method of sealing a ring.

[0014] Figure 6 is a graph depicting the quality of the seal ring crystal microstructure for various samples made with different metallurgies according to examples of the present invention. DETAILED DESCRIPTION

[0015] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0016] Figure 1 is a schematic diagram of an example machine 100 having a sealing ring according to an example of the present invention. Although the machine 100 is depicted as a mining truck-type machine, it can be any suitable machine, such as any type of loader, bulldozer, dump truck, skid steer loader, excavator, compactor, backhoe, combine, crane, drilling equipment, tank, trencher, tractor, combinations thereof, etc. As disclosed herein, the machine 100 is configured to use any suitable fuel for propulsion, such as diesel, electricity, hydrogen, various hydrocarbons, compressed natural gas (CNG), natural gas, LNG mixed with diesel, LNG mixed with gasoline, LNG mixed with kerosene, liquefied petroleum gas (LPG), combinations thereof, etc.

[0017] The machine 100 is shown as a mining truck, which is used, for example, to move mined materials, heavy construction materials, and / or equipment, and / or for road construction, building construction, other mining, paving, and / or construction applications. For example, such a machine 100 is used in situations where it is necessary to transport materials such as mineral ore, loose stone, gravel, soil, sand, concrete, and / or other materials at a worksite across a surface 102 at the worksite. It should be understood that the machine 100 may be in the form of any other type of suitable construction, mining, farming, military, and / or transportation machine.

[0018] like Figure 1 As shown, the example machine 100 includes a frame 104 and wheels 106. The wheels 106 are mechanically coupled to a drive system (not shown) to propel the machine 100. The machine 100 may include an engine (not shown) that may be of any suitable type, size, power output, etc. When powered, the engine rotates the wheels 106 via the wheel assemblies 108 to enable the machine 100 to traverse the surface 102. Figure 1 As shown in FIG. 1 as having a hub with a rubber tire, but in other examples, the wheel 106 may instead be in the form of a drum, a chain drive, a combination thereof, or the like.

[0019] The machine 100 includes a dump box 110 or other movable element that is configured to move, lift, carry, and / or dump material. For example, the dump box 110 can be used to pick up and transport dirt or mined ore from one location on the surface 102 to another location on the surface 102. The dump box 110 is actuated by one or more hydraulic systems 112 or any other suitable mechanical system. In some cases, the hydraulic system 112 is powered by an engine using fuel from a fuel tank 114, such as by powering a hydraulic pump (not shown) of the hydraulic system 112. It should be noted that in other types of machines (e.g., machines other than mining trucks), the hydraulic system 112 may be configured differently than the machine shown herein, may be used to operate elements other than the dump box 110, and / or the machine may not have a hydraulic system 112 at all.

[0020] Machine 100 may also include an operator station 116. Operator station 116 is configured to seat an operator (not shown). The operator, seated at operator station 116, interacts with various control interfaces and / or actuators within operator station 116 to control the movement of various components of machine 100 and / or the overall movement of machine 100 itself. Thus, the control interfaces and / or actuators within operator station 116 allow for control of the propulsion of machine 100 by controlling the operation of the engine. An electronic control module (ECM) 118 of machine 100 receives operator signals, such as accelerator signals, based at least in part on the operator's interaction with one or more control interfaces and / or actuators of machine 100. ECM 118 uses the operator signals to generate command signals to control various components of machine 100.

[0021] The machine 100 further includes any number of other components within the operator station 116 and / or at one or more other locations on the frame 104. These components may include, for example, position sensors (e.g., a global positioning system (GPS)), an air conditioning system, a heating system, a communication system (e.g., a radio, a Wi-Fi connection), a collision avoidance system, sensors, cameras, etc. These systems may be powered by any suitable mechanism, such as by using a direct current (DC) power source powered by the engine in conjunction with a generator (not shown) and / or an inverter (not shown), an alternating current (AC) power source powered by the engine and generator, and / or by a mechanical coupling to the engine.

[0022] The wheel assembly 108 will be relative to Figure 2106 so that the machine 100 can traverse the ground 102. Thus, the wheel assembly 108 includes rotating parts that allow the wheel 106 to rotate. These parts may include sealing rings, such as rotating sealing rings and / or static sealing rings. In some cases, the sealing rings may engage with each other in a face-to-face manner. For example, a rotatable sealing ring may contact a static (non-rotatable) sealing ring, such as in a face-to-face manner. Alternatively, a rotatable sealing ring may contact another rotatable sealing ring, such as in a face-to-face manner. In some cases, the sealing rings may be used to contain lubricant within the wheel assembly 108, such as within a cavity containing one or more ball bearings.

[0023] As disclosed herein, the sealing ring can be circular and / or annular. Therefore, the sealing ring can be formed using centrifugal casting or spin casting. The process of centrifugal casting can include spinning the casting mold while pouring molten metal into the rotating mold. The rotating mold can be oriented in any suitable direction relative to the normal of the earth. For example, the centrifugal casting mold can be oriented in a horizontal position or a vertical position relative to the direction of gravity of the earth. For example, a vertically oriented spin mold can be used to form the sealing ring disclosed herein so that the height of the sealing ring (e.g., in the axial direction) is relatively small compared to the width of the sealing ring (e.g., in the radial direction).

[0024] It should be understood that centrifugal casting may result in a different cooling distribution compared to more traditional casting processes (such as sand casting). For example, cooling can be enhanced in centrifugal casting compared to static casting such as sand casting. To the extent that it is desired to control the crystal microstructure of the sealing ring to meet performance metrics (e.g., leakage rate performance, life, durability, etc.), it is desirable to consider the different cooling distribution of centrifugal casting compared to more conventional casting processes. According to an example, a nickel (Ni)-based alloy as disclosed herein enables centrifugal casting of sealing rings. In other words, a sealing ring centrifugally cast using the metallurgy disclosed herein allows for a crystal structure of the sealing ring that is advantageous or desired for the cooling distribution of the centrifugally cast sealing ring. In some cases, a sealing ring manufactured using centrifugal casting and the alloy disclosed herein can have a crystal structure having a relatively larger amount of chromium carbide, chromium boride, or both chromium carbide and chromium boride than a sealing ring manufactured using a more conventional centrifugal casting alloy.

[0025] Nickel alloys as disclosed herein may include any type of chemical compound therein, such as any suitable elemental metal. As used herein, nickel alloys indicate metal alloys having a majority (e.g., greater than 50% Ni) therein. In some examples, the nickel alloy may include a chromium (Cr) content greater than at least 13.5 wt%, a boron (B) content less than 3 wt%, a carbon (C) content less than 2 wt%, and a Ni content greater than 65 wt%. In some cases, the nickel alloy may further include a silicon (Si) content less than 4 wt%. In further cases, the nickel alloy may include an iron (Fe) content less than 5 wt%. In further examples, the nickel alloys as disclosed herein may have a Cr content greater than at least 15.5 wt%, a B content less than 2.5 wt%, a C content less than 1.7 wt%, and a Ni content greater than 72 wt% but less than 75 wt%. In further examples, the nickel alloys disclosed herein may have a Cr content greater than at least 16 wt%, a B content less than 2.3 wt%, a C content less than 1.7 wt%, and a Ni content greater than 72.5 wt% but less than 74 wt%. In some or all of these cases, the nickel alloy may further include a Si content less than 4 wt%. Additionally, in some or all of these cases, the nickel alloy may include an Fe content less than 4.5 wt%.

[0026] In some cases, the nickel alloys disclosed herein may have a C and B to Cr content by weight of 0.25 or less (e.g., [[weight percent concentration of C] + [weight percent concentration of B]] / [weight percent concentration of Cr]). In other cases, the nickel alloys as disclosed herein may have a C and B to Cr content by weight of 0.24 or less. In further cases, the nickel alloys as disclosed herein may have a C and B to Cr content by weight of 0.23 or less. In still other cases, the nickel alloys as disclosed herein may have a C and B to Cr content by weight of 0.22 or less.

[0027] In some cases, the nickel alloys disclosed herein can have an atomic content of C and B to Cr of 1.2 or less (e.g., [[atomic concentration percentage of C] + [atomic concentration percentage of B]] / [atomic concentration percentage of Cr]). In other cases, the nickel alloys as disclosed herein can have an atomic content of C and B to Cr of 1.1 or less. In further cases, the nickel alloys as disclosed herein can have an atomic content of C and B to Cr of 1 or less. In other cases, the nickel alloys as disclosed herein can have an atomic content of C and B to Cr of 0.9 or less. In other cases, the nickel alloys as disclosed herein can have an atomic content of C and B to Cr of 0.8 or less. The following table shows example compositions of conventional nickel alloys that can be used for static casting (e.g., sand casting) and two example nickel alloys according to the present invention that can be used for centrifugal casting of the sealing ring 224 disclosed herein. It should be noted that the examples disclosed below are merely two different examples and that the present invention contemplates various ranges of element concentrations in the disclosed nickel alloys.

[0028]

[0029]

[0030] Table 1: Example compositions of conventional nickel alloys and example nickel alloys as disclosed herein.

[0031] It should be understood that the nickel-based alloys disclosed herein allow the seal ring 224 to be manufactured using a centrifugal casting process, which is more cost-effective than conventional static casting processes (such as sand casting). Therefore, the seal ring 224 can be formed using a less expensive process, and the nickel alloy formulations disclosed herein allow for a different cooling profile (e.g., faster cooling) than conventional casting processes. In other words, the nickel alloy formulations provide a desired grain structure and crystal morphology despite the faster cooling profile associated with centrifugal casting. Compared to seal rings 224 centrifugally cast from conventional alloys, the seal ring 224 formed from the nickel alloys described herein allows for improved oil leakage performance and / or wear performance. In some cases, compared to seal rings statically cast from conventional alloys, the seal ring 224 formed from the nickel alloys described herein allows for improved oil leakage performance and / or wear performance.

[0032] Figure 2 is an example according to the present invention having Figure 1 Schematic diagram of the environment 200 of the wheel assembly 108 of the machine 100 is depicted in FIG. Figure 1 As discussed, the machine 100 includes a wheel assembly 108, such as Figure 2The wheel assembly 108 includes a hub 202, a rotatable spindle 204 journaled with the hub 202 via a bearing 206, and the wheel 106 mounted to the rotatable spindle 204. The machine 100 includes a braking system 208 disposed with the wheel assembly 108 and configured to selectively stop rotation of the wheel 106 relative to the hub 202.

[0033] A seal assembly 210 constructed in accordance with the principles of the present invention can provide an operational seal between a first member 212 mounted to the hub 202 of the wheel assembly 108 and a second member 216 in the form of a brake housing of the brake system 208. The brake housing 214 is secured to the rotatable spindle 204 such that the brake housing 214 is rotatable relative to the first member 212 about an axis of rotation that is aligned with a longitudinal axis "LA" defined by the spindle 204. The seal assembly 210 is disposed between the first member 212 and the second member 216.

[0034] A second seal assembly 218 constructed in accordance with the principles of the present invention is provided to form a second operating seal between the first and second components 212, 216 of the machine 100, which are rotatable relative to each other about the longitudinal axis "LA." In one example, the first and second seal assemblies 210, 218 may be substantially identical. In other examples, the second seal assembly 218 may be different from the first seal assembly 210.

[0035] A first seal assembly 210, in the form of a metal-to-metal seal assembly, is disposed in a first seal cavity 220 that extends axially between a first component 212 and a second component 218. A second component 216, in the form of a brake housing, is rotatable relative to the first component 212 about a longitudinal axis "LA," with the first seal assembly 210 providing an operational seal therebetween. A second seal assembly 218 is similarly disposed in the second seal cavity 222. In some examples, the first and second seal assemblies 210, 218 may be used to retain brake cooling fluid and / or lubricant. In other examples, as will be appreciated by those skilled in the art, seal assemblies constructed according to the principles of the present invention may be used in other applications.

[0036] The first member 212 and the second member 216 can be rotatable relative to each other about a longitudinal axis "LA," with the seal assembly 210 providing a mechanism for fluidically sealing the first and second members 212, 216, with an operating seal ring 224 therebetween. In some examples, the first member 212 can include a component mounted to or otherwise stationary relative to the frame 104, and the second member 216 can include a component rotationally movable relative to the first member 212 about the longitudinal axis "LA." In other examples, the second member 216 can be stationary and the first member 212 rotatable relative to the frame 104. However, it should be understood that the use of the terms "first," "second," etc., herein is merely for ease of reference and is not intended to be limiting in any way. The illustrated first and second seal assemblies 210, 216 are substantially identical to one another. Therefore, it should be understood that a description of one seal assembly also applies to the other.

[0037] The first sealing assembly 210 includes at least one sealing ring 224 and / or one or more load rings (not shown), which can all be annular. In some cases, there can be two sealing rings 224 and / or two load rings. The sealing ring 224 and the load ring are arranged in the first sealing cavity 220. In some cases, there can be two sealing rings 224 in the first sealing assembly 210, and the two sealing rings are arranged in an adjacent relationship to each other (e.g., face to face). According to an example of the present invention, the sealing ring 224 is made of a nickel-based alloy disclosed herein. Further, according to an example of the present invention, the sealing ring 224 can be manufactured using a centrifugal casting technique. Alternatively, the sealing ring 224 can be manufactured using a static casting technique (such as sand casting) but using the nickel alloy disclosed herein.

[0038] It should be understood that the sealing ring 224 and the wheel assembly 108 and its constituent components are merely one example of a sealing ring 224 and wheel assembly 108. Indeed, the methods and materials (e.g., nickel alloys) disclosed herein may be applied to any suitable variation of the sealing ring 224 and wheel assembly 108. Furthermore, the methods and materials disclosed herein may be applied to any other element or component, such as any suitable component of the machine 100. The inventions herein may further be used to manufacture and / or fabricate other annular rings, cylindrical rings, and / or tubular rings associated with the machine 100 or any other suitable application.

[0039] Figure 3 According to an example of the present invention Figure 1is a schematic diagram of a top view of the sealing ring 224 of the machine 100 depicted in FIG. As shown, the sealing ring 224 can be any suitable size or shape, such as annular, tubular, cylindrical, etc. In some examples, the sealing flange 300 can include a sealing surface 302. The sealing surface 302 can include a sealing band 306 disposed near an outer periphery 308 of the sealing flange 300 and an inner relief area 310 disposed between the sealing band 306 (shown as a hatched area for illustrative purposes) and an inner periphery 312 of the sealing ring 224.

[0040] The inner relief area 310 can taper between the sealing band 306 and the inner periphery 312, such that the inner periphery 312 is axially displaced from the sealing band 306. An inner radial edge 314 can demarcate the sealing band 306 and the inner relief area. The sealing surface 302 can have any suitable width, such as a width in the range of approximately 10 millimeters (mm) to approximately 500 mm. Similarly, the inner relief area 310 can have any suitable width, such as a width in the range of approximately 10 mm to approximately 500 mm. It should be understood that the above values ​​are merely examples, and the sealing surface 302 and / or the inner relief area 310 can have any suitable width. It should be further understood that the sealing ring 224 depicted herein is merely an example. It should be understood that the materials and methods disclosed herein can be used to manufacture the sealing ring 224 or other components having more, fewer, or different features and / or geometries.

[0041] Figure 4 According to an example of the present invention Figure 3 FIG2 is a schematic diagram of a cross-sectional view of a sealing ring 224. The sealing ring 224 includes a cylindrical body 400 and a sealing flange 300. The cylindrical body 400 extends along a longitudinal axis "LA" between a load end 402 and a sealing end 404, with the sealing end 404 being in opposing relation to the load end 402. The cylindrical body 400 includes a substantially cylindrical inner periphery 312 and an inclined load surface 406 in outer radially spaced relation to the inner periphery 312.

[0042] The sealing flange 300 is disposed at the sealing end 304. The sealing flange 300 radially protrudes from the cylindrical body 400 to its outer periphery 308. A sealing band 306 is disposed on the sealing flange 300 and extends radially relative to the longitudinal axis "LA". The sealing band 306 can be substantially flat in cross-section between the inner radial edge 314 and the outer periphery 308. In some examples, the sealing band 306 can include an outer relief region disposed adjacent the outer periphery 308 that is beveled or tapered.

[0043] In some examples, the seal ring 224 for the seal assembly is made from an alloy in accordance with the present invention. In an example, the alloy for the seal ring 224 of the wheel assembly 108 in accordance with the principles of the present invention includes a reduced Ni content relative to conventional alloys used to make the seal ring 224, a reduced C content relative to conventional alloys used to make the seal ring 224, a reduced B content relative to conventional alloys used to make the seal ring 224, and / or an increased Cr content relative to conventional alloys used to make the seal ring 224. In such an example, the nickel alloy can include Fe in a range between 2 wt% and 6 wt% and Si in a range between 1 wt% and 4.5 wt%. In an example, the Si content of the nickel alloy can be adjusted to maintain the castability of the iron-containing nickel alloy.

[0044] It should be understood that, in other examples, alloys conforming to the principles of the present invention may be used to manufacture other types of seal rings having configurations different from the configuration of the seal ring 224 described herein, such as, heavy-duty double-sided metal face seals using Belleville washers; other types of double-conical seal rings having different load surfaces and / or sealing faces and / or used in conjunction with load rings or torus of different shapes; and other seals for other sealing assemblies, as will be understood by those skilled in the art.

[0045] In an example, an alloy for seal ring 224 according to the present invention includes between 2% and 6% Fe by weight, between 1% and 4.5% Si by weight, greater than 13.5% Cr by weight, and at least 65% Ni by weight. In at least some such examples, the alloy includes between greater than 13.5% and no more than 18% Cr by weight. In at least some such examples, the alloy includes between 65% and 75% Ni by weight. In an example, the alloy also includes between 1% and 3% B by weight. In an example, the alloy also includes between 0.3% and 2% C by weight. In some examples, the alloy does not contain more than trace amounts of molybdenum, cobalt, manganese, copper, or any two of the foregoing, any three of the foregoing, or all of the foregoing. According to an example of the present invention, an example nickel alloy composition may include 73.2% Ni by weight, 0.8% C by weight, 3.7% Si by weight, 16.2% Cr by weight, 2.2% B by weight, and 4.0% Fe by weight. According to an example of the present invention, another example nickel alloy composition may include 72.5 wt% Ni, 1.5 wt% C, 3.7 wt% Si, 16.2 wt% Cr, 2.2 wt% B and 4.0 wt% Fe. It should be understood that the present invention contemplates suitable nickel alloy compositions other than the two specific compositions described above.

[0046] The seal ring 224 manufactured using centrifugal casting and the nickel alloys disclosed herein provides a preferential crystal structure that allows for good sealing performance and wear performance of the seal ring 224. The seal ring 224 manufactured with the nickel alloys discussed herein provides a larger Cr-rich hard phase, which allows for relatively good sealing / leakage performance and relatively good wear resistance.

[0047] Figure 5 is a diagram illustrating an example of a method for manufacturing a Figure 3 Flowchart of an example method 500 for forming a seal ring 224. The method 500 may be performed in any suitable location, such as a foundry, factory, laboratory, forge, or the like.

[0048] At block 502, a nickel alloy may be prepared. Nickel alloys as disclosed herein may enable centrifugal casting of the sealing ring 224. The nickel alloy may be prepared using any suitable mechanism, such as adding target elements to a crucible according to the recommendations disclosed herein. The proportionately added elements may then be heated within the crucible to mix the metals in a liquid phase. This mixed liquid phase of the nickel alloy may then be used for casting or other processes.

[0049] Nickel alloys as disclosed herein may include any type of chemical compound therein, such as any suitable elemental metal. As used herein, nickel alloys refer to metal alloys having a majority (e.g., greater than 50% Ni) therein. In some examples, the nickel alloy may include a Cr content greater than at least 13.5 wt%, a B content less than 3 wt%, a C content less than 2 wt%, and a Ni content greater than 65 wt%. In some cases, the nickel alloy may further include a Si content less than 4 wt%. In further cases, the nickel alloy may have an Fe content less than 5 wt%. In further examples, the nickel alloys as disclosed herein may have a Cr content greater than at least 15.5 wt%, a B content less than 2.5 wt%, a C content less than 1.7 wt%, and a Ni content greater than 72 wt% but less than 75 wt%. In yet further examples, the nickel alloys as disclosed herein may have a Cr content greater than at least 16 wt%, a B content less than 2.3 wt%, a C content less than 1.7 wt%, and a Ni content greater than 72.5 wt% but less than 74 wt%. In some or all of these cases, the nickel alloy may further include a Si content of less than 4 wt%. Additionally, in some or all of these cases, the nickel alloy may have a Fe content of less than 4.5 wt%.

[0050] In some cases, the nickel alloys disclosed herein may have a C and B to Cr content by weight of 0.25 or less (e.g., [[weight percent concentration of C] + [weight percent concentration of B]] / [weight percent concentration of Cr]). In other cases, the nickel alloys as disclosed herein may have a C and B to Cr content by weight of 0.24 or less. In further cases, the nickel alloys as disclosed herein may have a C and B to Cr content by weight of 0.23 or less. In still other cases, the nickel alloys as disclosed herein may have a C and B to Cr content by weight of 0.22 or less.

[0051] In some cases, the nickel alloys disclosed herein can have an atomic content of C and B to Cr of 1.2 or less (e.g., [[atomic concentration percentage of C] + [atomic concentration percentage of B]] / [atomic concentration percentage of Cr]). In other cases, the nickel alloys as disclosed herein can have an atomic content of C and B to Cr of 1.1 or less. In further cases, the nickel alloys as disclosed herein can have an atomic content of C and B to Cr of 1 or less. In other cases, the nickel alloys as disclosed herein can have an atomic content of C and B to Cr of 0.9 or less. In other cases, the nickel alloys as disclosed herein can have an atomic content of C and B to Cr of 0.8 or less. The following table shows example compositions of nickel alloys according to the present invention.

[0052]

[0053]

[0054]

[0055] Table 2: Example compositions of nickel alloys according to the present invention.

[0056] At frame 504, a rough sealing ring can be formed from a nickel alloy and by using centrifugal casting. The centrifugal casting process can include a rotary casting mold, while molten metal (e.g., a nickel alloy prepared by the process of frame 502) is poured into the rotary mold. The rotary mold can be oriented in any suitable direction relative to the normal of the earth. For example, the centrifugal casting mold can be oriented in a horizontal position or a vertical position relative to the direction of gravity of the earth. For example, the cast seal disclosed herein can be formed using a vertically oriented rotary mold so that the height of the sealing ring (e.g., in the axial direction) is relatively small compared to the width of the sealing ring (e.g., in the radial direction). The mold can be rotated at any suitable speed.

[0057] The rough sealing ring can also be manufactured using any other suitable technology, such as by stamping and forming or by static casting (e.g., sand casting). In an example, the rough sealing ring can be produced using an alloy in accordance with the principles of the present invention, so that the rough sealing ring is relatively softer than a conventional rough sealing ring. In other examples, the rough sealing ring can be produced using an alloy in accordance with the principles of the present invention, so that the rough sealing ring is relatively harder than a conventional rough sealing ring. In an example, the rough sealing ring can be produced using an alloy in accordance with the principles of the present invention, so that the sealing ring has a hardness between 48HRC and 57HRC. In other examples, the rough sealing ring can be produced using an alloy in accordance with the principles of the present invention, so that the sealing ring has a hardness between 50HRC and 55HRC. The above hardness values ​​are merely examples, and the hardness of the rough sealing ring can be greater or less than the examples discussed.

[0058] At frame 506, the rough seal ring can be machined to manufacture the seal ring. In some cases, this process can be optional. When this process is not used, after the centrifugal casting process, the seal ring 224 may already be in its final form. The seal ring 224 can be machined by any suitable technique, such as by lathe turning using a lathe and / or grinding using a grinder. The seal ring 224 can be machined so that the thickness of the seal flange is within a predetermined tolerance, the seal bevel angle is within a predetermined tolerance, and, for example, other dimensional tolerances are met. In some cases, when the seal ring 224 has a hardness between 50HRC and 55HRC, the machinability of the seal ring 224 is enhanced. The sealing surface can be ground using any suitable technique, such as using spherical grinding to define an inner relief area. The sealing surface can be ground using any suitable technique, such as grinding with a flat abrasive, for example, to flatten the sealing band.

[0059] At block 508, the sealing ring is polished. This polishing process removes any excessive roughness or burrs on the sealing ring. At this point, the sealing ring is ready for testing, packaging, distribution, and / or sale. At this point, the sealing ring 224 can be installed in the wheel assembly 108 or any other suitable application and / or device and used.

[0060] It should be appreciated that the process of method 500 allows for the use of cost-effective mechanisms, such as centrifugal casting, to manufacture the seal ring 224. This allows for the use of a lower cost seal ring 224. The seal ring 224 made from the nickel alloy disclosed herein also provides a crystalline structure that results in low leakage and high durability.

[0061] It should be noted that some operations of method 500 may not be performed in the order presented, have additional elements, and / or not have some elements. Some operations of method 500 may further occur substantially simultaneously, and therefore may end in an order different from the order of operations shown above.

[0062] Figure 6 600 is a graph depicting the quality of the sealing ring crystal microstructure of various samples made with different metallurgies according to an example of the present invention. As shown, various samples with different metallurgies are used to manufacture sealing ring 224 using centrifugal casting. The C atomic content, B atomic content and Cr atomic content of each of these samples are measured. The measurement technique used for these determinations is X-ray fluorescence (XRF), however, any suitable technique can be used to measure the atomic content of the various samples. In some cases, if the composition is determined during the formulation of the nickel alloy itself, the measurement may not even be necessary. From the perspective of leakage measurement and / or durability, it is recorded whether the crystal morphology of the various samples is good or poor. A good crystal structure can include a relatively high level of chromium carbide and / or chromium boride compared to a poor crystal structure.

[0063] As shown in graph 600, the ratio of C and B atoms to Cr atoms of a nickel alloy can be plotted, thereby predicting which nickel alloys may be suitable for centrifugal casting purposes. In other words, the atomic content of C and B to Cr (e.g., [[atomic concentration percentage of C] + [atomic concentration percentage of B]] / [atomic concentration percentage of Cr]) can predict whether the seal ring 224 can produce a desired crystal morphology when centrifuged therefrom. As shown, an atomic content of C and B to Cr of 1.1 can depict a nickel alloy that is likely to produce a desired crystal structure with relatively good performance (low leakage rate, high durability, etc.). Therefore, according to examples of the present invention, nickel alloys having an atomic C and B to Cr ratio of 1.1 or less can be used to manufacture the seal ring 224 using centrifugal casting.

[0064] In other cases, as disclosed herein, nickel alloys having an atomic content of C, B, and Cr of 1 or less can be used to manufacture the seal ring 224 using centrifugal casting. In further cases, as disclosed herein, nickel alloys having an atomic content of C, B, and Cr of 0.9 or less can be used to manufacture the seal ring 224 using centrifugal casting. In other cases, as disclosed herein, nickel alloys having an atomic content of C, B, and Cr of 0.8 or less can be used to manufacture the seal ring 224 using centrifugal casting.

[0065] Industrial Applicability

[0066] The present invention describes materials, apparatus, and methods for forming high-quality seal rings 224, such as for use in mining machines (e.g., mining trucks), using low-cost manufacturing processes such as centrifugal casting. Centrifugal casting offers cost advantages over conventional processes for forming seal rings, such as static casting (e.g., sand casting). However, the different cooling profile associated with centrifugal casting renders conventional alloys that are otherwise used for static casting less efficient. In other words, the use of conventional alloys to form seal rings 224 using centrifugal casting may result in a crystal microstructure of the seal ring 224 that increases oil leakage levels, as measured by pressure-velocity testing. Furthermore, seal rings 224 formed from conventional alloys may result in greater wear and tear than desired.

[0067] By using the nickel alloy disclosed herein, the seal ring 224 formed by centrifugal casting has a crystalline structure that results in good oil leakage and good durability of the seal ring 224. Compared to conventional alloys used in centrifugal casting processes, the seal ring 224 formed using the disclosed nickel alloy has a higher proportion of hard chromium carbide and chromium boride microstructures. These microstructures enable the seal ring 224 manufactured according to the present invention to have improved leakage performance and greater durability at a lower cost.

[0068] The sealing ring 224 formed according to the present invention produces superior financial metrics. For example, the cost of the sealing ring 224 can be reduced due to the use of lower-cost manufacturing techniques. Additionally, the lower leakage rate results in a reduced frequency of preventative maintenance or other downtime. Furthermore, the greater durability of the sealing ring 224 results in a reduced frequency of replacement of the sealing ring 224 on the machine 100. The reduced frequency of preventative maintenance and / or the reduced frequency of replacement of the sealing ring 224 results in reduced downtime of the machine 100 at the worksite, which improves the availability and efficient use of the machine for the task at hand. As disclosed herein, the lower cost and greater availability of the equipment due to the improved sealing ring 224 results in greater financial metrics, such as return on investment (ROI) and / or return on capital (ROC).

[0069] While the components, materials, and methods of centrifugally casting the seal ring 224 are discussed in the context of a machine 100, such as a mining truck, it should be understood that the invention herein can be applied to a variety of machines and vehicles across a variety of industries, such as construction, mining, farming, transportation, military, combinations thereof, and the like. For example, the seal ring 224 disclosed herein can be applied to excavators in the mining industry or harvesters in the agricultural industry. Additionally, the seal ring 224 disclosed herein can be applied to other industries, such as aviation, robotics, and the like.

[0070] Although various aspects of the present invention have been particularly shown and described with reference to the above examples, it will be understood by those skilled in the art that various additional examples may be contemplated by modifying the disclosed machines, systems, and methods without departing from the spirit and scope of the disclosure. Such examples should be understood to fall within the scope of the present invention as determined by the claims and any equivalents thereof.

[0071] Recitation of ranges of values ​​herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein.

Claims

1. A sealing ring (224), comprising: a body (400) that is generally annular and has a sealed end (404); as well as a sealing flange (300) provided at the sealing end (404) of the body (400), the sealing flange (300) surrounding the body (400), The sealing ring (224) is made of an alloy comprising: Less than 4wt% silicon (Si), More than 13.5wt% chromium (Cr), Less than 3 wt% of boron (B), less than 2 wt% carbon (C), and Greater than 70 wt% nickel (Ni).

2. The sealing ring (224) of claim 1, wherein the sealing flange (300) protrudes radially from the body (400) to a distal periphery (308) of the sealing flange (300), the sealing flange (300) including a sealing surface (302) that is annular and disposed adjacent the distal periphery (308).

3. The seal ring (224) of claim 1, wherein the alloy further comprises: Less than 5 wt% iron (Fe).

4. The seal ring (224) of claim 1, wherein the alloy further comprises: More than 15 wt% Cr.

5. The seal ring (224) of claim 1, wherein the atomic concentration of B plus the atomic concentration of C divided by the atomic concentration of Cr is less than 1.

1.

6. The seal ring (224) of claim 1, wherein the alloy further comprises: More than 16wt% Cr, less than 2.5 wt% of B, and Less than 1.6 wt% C.

7. An alloy for a sealing ring (224), the alloy comprising: 2 wt% to 5 wt% of iron (Fe); greater than 13.5 wt% chromium; More than 65 wt% nickel (Ni); 1 wt% to 3 wt% of boron (B); and Less than 2 wt% carbon (C).

8. The alloy of claim 7, further comprising: Less than 4 wt% silicon (Si).

9. The alloy of claim 7, further comprising: More than 15.5wt% Cr, less than 2.5 wt% of B, and Less than 1.6 wt% C.

10. The alloy of claim 7, wherein the atomic concentration of B plus the atomic concentration of C divided by the atomic concentration of Cr is less than 1.1.

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