Bearing and laser manufacturing method, system thereof

Abstract

The application discloses a bearing and a laser manufacturing method and system thereof, and particularly relates to the technical field of laser material processing. The laser manufacturing method of the bearing comprises the following steps: determining a eutectic high-entropy alloy material for the bearing; and taking the eutectic high-entropy alloy material as cladding material, forming a cladding layer on a surface of a bearing base body by means of a double-beam cladding laser in a laser cladding device, thereby obtaining the bearing. The application realizes an efficient and stable preparation process of the cladding layer of the high-performance bearing.

Description

Technical Field

[0001] This application relates to the field of laser material processing technology, and in particular to bearings and their laser manufacturing methods and systems. Background Technology

[0002] In modern industry, bearings are key components of various mechanical equipment, and their performance directly affects the operational stability and service life of the equipment.

[0003] Traditional bearing manufacturing methods often suffer from low efficiency and insufficient stability in the preparation of the cladding layer, making it difficult to meet the stringent quality and performance requirements of high-performance bearings. Traditional cladding technology is slow, resulting in long production cycles. Furthermore, the bonding between the cladding layer and the bearing substrate is unstable during the preparation of the bearing cladding layer, affecting the overall performance and reliability of the bearing. Summary of the Invention

[0004] The main purpose of this application is to provide a bearing and its laser manufacturing method and system, which aims to solve the technical problems of the inefficiency and instability of the existing high-performance bearing cladding layer preparation process.

[0005] To achieve the above objectives, this application provides a laser manufacturing method for bearings, applied to a laser manufacturing system for bearings, the system including laser cladding equipment, and the method comprising: Determine the eutectic high-entropy alloy material for bearings; The eutectic high-entropy alloy material is used as the cladding material, and a cladding layer is formed on the surface of the bearing substrate by a dual-beam cladding laser in the laser cladding equipment to produce the bearing.

[0006] In one feasible embodiment, the laser cladding equipment includes a motion platform, a material source, and a laser source. The laser source includes a first cladding light source and a second cladding light source. The step of using the eutectic high-entropy alloy material as the cladding material and forming a cladding layer on the bearing substrate surface using a dual-beam cladding laser in the laser cladding equipment includes: Control the bearing base on the motion platform to move along a preset trajectory; The material source is controlled to deliver the eutectic high-entropy alloy material; The first cladding light source is controlled to emit a first cladding beam, which pre-treats the surface of the bearing substrate to form a microtexture. The second cladding light source is controlled to emit a second cladding beam, which clads the eutectic high-entropy alloy material onto the surface of the bearing substrate to form the cladding layer.

[0007] In one feasible embodiment, the system further includes a laser polishing apparatus, and after the step of forming a cladding layer on the bearing substrate surface by a dual-beam cladding laser in the laser cladding apparatus, the system further includes: The surface of the cladding layer is polished using a dual-beam polishing laser from the laser polishing equipment, wherein the surface roughness Ra of the cladding layer after polishing is less than 0.1 μm.

[0008] In one feasible embodiment, the dual-beam polishing laser includes a first polishing beam and a second polishing beam, wherein the first polishing beam includes a continuous laser for rough polishing; and the second polishing beam includes a pulsed laser for mirror polishing.

[0009] In one feasible embodiment, a reinforcing layer is formed on the surface of the cladding layer during the polishing process.

[0010] In one feasible embodiment, the thickness of the cladding layer is 0.01 mm to 0.2 mm.

[0011] In one feasible embodiment, the step of determining the eutectic high-entropy alloy material for the bearing includes: Determine the target phase structure and target performance parameters of the eutectic high-entropy alloy material; Based on a preset machine learning model, within a preset composition ratio range of the eutectic high-entropy alloy material, the predicted phase structure and target performance parameters are output. When the predicted phase structure matches the target phase structure and the target performance parameters match the target performance parameters, the composition ratio of the eutectic high-entropy alloy material corresponding to the predicted phase structure and the target performance parameters is determined as the target composition ratio.

[0012] This application provides a laser manufacturing system for bearings, the system comprising: Laser cladding equipment is used to form a cladding layer on the surface of a bearing substrate; The control module is used to determine the eutectic high-entropy alloy material for manufacturing the bearing; the eutectic high-entropy alloy material is used as the cladding material, and a cladding layer is formed on the surface of the bearing substrate by the dual-beam cladding laser in the laser cladding equipment to obtain the bearing.

[0013] In one feasible embodiment, the system further includes a laser polishing device for polishing the surface of the cladding layer using a dual-beam polishing laser.

[0014] This application also provides a bearing manufactured by the laser manufacturing method described above.

[0015] One or more technical solutions proposed in this application have at least the following technical effects: First, a eutectic high-entropy alloy material for bearings is determined. This eutectic high-entropy alloy material itself possesses excellent properties, such as high strength, high hardness, good wear resistance, and corrosion resistance, providing a foundation for preparing a high-performance bearing cladding layer. Second, the eutectic high-entropy alloy material is used as the cladding material, and a cladding layer is formed on the surface of the bearing substrate using a dual-beam cladding laser in a laser cladding device, thus producing the bearing. Third, compared to a single beam, using a dual-beam cladding laser allows for more uniform heating and melting of the cladding material, resulting in better fusion with the bearing substrate, reducing defects such as porosity and cracks in the cladding layer, and improving the quality and stability of the cladding layer. Simultaneously, the dual beam accelerates the cladding speed, allowing more cladding work to be completed in the same amount of time, significantly improving preparation efficiency. Therefore, this application embodiment achieves an efficient and stable preparation process for the cladding layer of high-performance bearings. Attached Figure Description

[0016] Figure 1 This is a schematic flowchart of the laser manufacturing method for bearings involved in the embodiments of this application; Figure 2 A schematic diagram illustrating the process of determining the preset machine learning model involved in the embodiments of this application; Figure 3 This is a schematic diagram of the first cladding beam and the second cladding beam involved in the embodiments of this application; Figure 4 This is a schematic diagram of the dual-beam laser polishing process involved in the embodiments of this application; Figure 5 This is a process flow diagram of the laser manufacturing method for bearings involved in the embodiments of this application; Figure 6 This is a schematic diagram of the structure of the laser manufacturing system for bearings involved in the embodiments of this application; Figure 7 This is a schematic diagram of the laser cladding equipment involved in the embodiments of this application.

[0017] Explanation of reference numerals in the attached figures: 10. Laser cladding equipment; 110. Laser source; 111. First cladding light source; 112. Second cladding light source; 120. Motion platform; 130. Material source; 140. Chiller; 20. Control module; 30. Laser polishing equipment.

[0018] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall apply. Reagents or instruments whose manufacturers are not specified are all conventional products that can be purchased commercially.

[0020] The following detailed description, with appropriate reference to the accompanying drawings, discloses embodiments of the bearing and its laser manufacturing method and system of this application. However, unnecessary detailed descriptions may be omitted. For example, detailed descriptions of well-known matters and repetitive descriptions of essentially identical structures may be omitted. This is to avoid unnecessarily lengthy descriptions and to facilitate understanding by those skilled in the art. Furthermore, the accompanying drawings and the following description are provided for the purpose of enabling those skilled in the art to fully understand this application and are not intended to limit the subject matter of the claims.

[0021] The "range" disclosed in this application is defined by a lower limit and an upper limit. A given range is defined by selecting a lower limit and an upper limit, which define the boundaries of a particular range. Ranges defined in this way can include or exclude endpoints and can be arbitrarily combined; that is, any lower limit can be combined with any upper limit to form a range. For example, if ranges of 60~120 and 80~110 are listed for a specific parameter, it is also expected that ranges of 60~110 and 80~120 are also included. Furthermore, if minimum range values ​​of 1 and 2 are listed, and if maximum range values ​​of 3, 4, and 5 are listed, then the following ranges are all expected: 1~3, 1~4, 1~5, 2~3, 2~4, and 2~5. In this application, unless otherwise stated, the numerical range "a~b" represents a shortened representation of any combination of real numbers between a and b, where a and b are real numbers. For example, the numerical range "0~5" indicates that all real numbers between "0~5" have been listed in this article; "0~5" is simply a shortened representation of these numerical combinations. Furthermore, when a parameter is stated as an integer ≥2, it is equivalent to disclosing that the parameter is, for example, an integer such as 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, etc.

[0022] Unless otherwise specified, all embodiments and optional embodiments of this application can be combined to form new technical solutions.

[0023] Unless otherwise specified, all technical features and optional technical features of this application may be combined to form new technical solutions.

[0024] Unless otherwise specified, all steps of this application may be performed sequentially or randomly, preferably sequentially. For example, if the method includes steps (a) and (b), it means that the method may include steps (a) and (b) performed sequentially, or it may include steps (b) and (a) performed sequentially. For example, if the method may also include step (c), it means that step (c) may be added to the method in any order. For example, the method may include steps (a), (b), and (c), or it may include steps (a), (c), and (b), or it may include steps (c), (a), and (b), etc.

[0025] Unless otherwise specified, the terms "comprising" and "including" as used in this application can be open-ended or closed-ended. For example, "comprising" and "including" can mean that other components not listed may also be included, or that only the listed components may be included.

[0026] Unless otherwise specified, the term "or" is inclusive in this application. For example, the phrase "A or B" means "A, B, or both A and B". More specifically, the condition "A or B" is satisfied by any of the following conditions: A is true (or exists) and B is false (or does not exist); A is false (or does not exist) and B is true (or exists); or both A and B are true (or exist).

[0027] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the technical solution of this application is further described below in conjunction with the accompanying drawings and embodiments. However, this application is not limited to the listed embodiments, but should also include any other well-known modifications within the scope of the claims made in this application.

[0028] The term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of this application. The phrase "in one embodiment" appearing in different places throughout this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0029] Traditional bearing manufacturing methods often suffer from inefficiencies and insufficient stability in preparing the cladding layer, making it difficult to meet the stringent quality and performance requirements of high-performance bearings. On one hand, traditional cladding technology is slow, resulting in long production cycles and high costs, which cannot meet the needs of large-scale industrial production. On the other hand, cladding layers prepared by traditional methods often exhibit poor performance in terms of bonding strength, hardness, and wear resistance, and are prone to defects such as cracks and porosity, affecting the overall performance and reliability of the bearing.

[0030] One or more technical solutions proposed in this application have at least the following technical effects: First, a eutectic high-entropy alloy material for bearings is determined. This eutectic high-entropy alloy material itself possesses excellent properties, such as high strength, high hardness, good wear resistance, and corrosion resistance, providing a foundation for preparing a high-performance bearing cladding layer. Second, the eutectic high-entropy alloy material is used as the cladding material, and a cladding layer is formed on the surface of the bearing substrate using a dual-beam cladding laser in a laser cladding device, thus producing the bearing. Third, compared to a single beam, using a dual-beam cladding laser allows for more uniform heating and melting of the cladding material, resulting in better fusion with the bearing substrate, reducing defects such as porosity and cracks in the cladding layer, and improving the quality and stability of the cladding layer. Simultaneously, the dual beam accelerates the cladding speed, allowing more cladding work to be completed in the same amount of time, significantly improving preparation efficiency. Therefore, this application embodiment achieves an efficient and stable preparation process for the cladding layer of high-performance bearings.

[0031] To better understand the technical solution of this application, a detailed description will be provided below in conjunction with the accompanying drawings and specific implementation methods.

[0032] The first aspect of this application provides a laser manufacturing method for bearings, applied to a laser manufacturing system for bearings. The system includes laser cladding equipment, as described above. Figure 1 The methods include: Step S10: Determine the eutectic high-entropy alloy material for the bearing; In one feasible embodiment, in order to manufacture high-performance bearings, it is crucial to select the appropriate material for the bearing cladding. Determining the eutectic high-entropy alloy material used for the bearing is the foundation of the entire manufacturing process and determines the performance and quality of the final bearing.

[0033] Alternatively, EHEAs (Eutectic High-Entropy Alloys) are a novel type of alloy material that combines the advantages of eutectic alloys and high-entropy alloys. High-entropy alloys are typically composed of multiple main elements with atoms randomly distributed in the crystal lattice, exhibiting high mixing entropy. This allows the alloy to possess excellent mechanical properties, such as high strength, high hardness, good wear resistance, and corrosion resistance. Eutectic structures, on the other hand, possess a uniform microstructure and good casting properties.

[0034] Optionally, the typical composition of eutectic high-entropy alloy materials consists of five or more main elements (such as Fe, Cr, Ni, Co, Al, Nb, etc.), with each element having an atomic percentage between 5% and 35%. Through precise proportioning, in-situ self-generated composite material structures are formed, such as regular lamellar or fibrous arrangements of FCC (Face-Centered Cubic) and BCC (Body-Centered Cubic Ordered Phase) / Laves (Laves Phase). This unique microstructure gives EHEAs a high hardness and good toughness match, where the hard phase provides wear resistance and the tough phase inhibits crack propagation, solving the brittleness bottleneck of ceramic materials; it also has excellent high-temperature stability, with the high-entropy effect and hysteresis diffusion effect slowing down the coarsening of the high-temperature structure; furthermore, it also has strong corrosion resistance, where the Cr-rich / Ni phase forms a dense passivation film.

[0035] Optionally, the high-entropy alloy material offers flexibility in composition design, allowing for the control of the eutectic phase ratio and interlamellar spacing by adjusting element proportions, thereby enabling on-demand design of hardness and toughness.

[0036] For example, common materials used for bearing coatings include GCr15 bearing steel, Si3N4 ceramic, and M50 high-temperature steel. Table 1 compares the performance of CoCrFeNiNb0.5, a high-entropy alloy containing the Laves phase, with the aforementioned materials for bearing coatings.

[0037] Table 1. Performance comparison of typical bearing materials and eutectic high-entropy alloy (CoCrFeNiNb0.5).

[0038]

[0039] The results in Table 1 show that the high-entropy alloy material CoCrFeNiNb0.5 containing the Laves phase still maintains a hardness of HV>550 at a high temperature of 800℃, which is far superior to M50 high-temperature bearing steel (hardness decay of >30% at 300℃), and can meet the requirements of aero-engine main shaft bearings.

[0040] For example, the wear resistance of FeCrMnxAlCu high-entropy alloy material used in high-speed rail bearings can reach more than 10 times that of GCr15 bearing steel. This is because during the wear process, Mn elements are oxidized to generate a high-hardness (Fe-Mn)Al6 ternary phase, forming a self-reinforcing effect.

[0041] In one feasible implementation, step S10, determining the eutectic high-entropy alloy material for the bearing, includes: Step S110: Determine the target phase structure and target performance parameters of the eutectic high-entropy alloy material; In one feasible embodiment, the phase structure and performance parameters that the eutectic high-entropy alloy material should possess are determined, providing direction and standards for the subsequent design, composition adjustment and manufacturing process selection of the eutectic high-entropy alloy material, thereby ensuring that the final bearing meets specific usage requirements and performance.

[0042] Optionally, phase structure refers to the types, morphologies, distributions, and other characteristics of different phases in a material. For eutectic high-entropy alloys used in bearings, different phase structures can significantly affect their performance. For example, certain phase structures may give the material higher hardness, better toughness, or superior wear resistance. By determining the target phase structure, the required microstructure characteristics of the material are clarified, providing an important reference standard for subsequent selection of suitable component ratios.

[0043] Optionally, target performance parameters refer to the various performance indicators that the material needs to achieve, such as hardness, strength, toughness, coefficient of thermal expansion, and corrosion resistance. These parameters directly affect the bearing's performance in actual use. For example, a bearing needs sufficient hardness to resist wear, appropriate toughness to prevent fracture, and good corrosion resistance to adapt to different working environments. Determining the target performance parameters provides specific performance requirements for subsequently selecting a suitable eutectic high-entropy alloy material composition.

[0044] Step S120: Based on the preset machine learning model, within the preset composition ratio range of the eutectic high-entropy alloy material, output the predicted phase structure and target performance parameters. In a feasible embodiment, the target phase structure and target performance parameters of the eutectic high-entropy alloy material have been determined in step S110. Eutectic high-entropy alloys have complex compositions with numerous combinations of different elements in various proportions. Traditional experimental methods are not only inefficient but also costly. Therefore, by using a pre-defined machine learning model to predict within a pre-defined composition ratio range, it is possible to quickly and efficiently screen out compositional combinations that may meet the target requirements, providing valuable reference for subsequent material preparation.

[0045] Optionally, the preset machine learning model is a trained model built upon extensive experimental data and materials science knowledge. The preset machine learning model learns the complex relationships between the compositional proportions, phase structure, and performance parameters of eutectic high-entropy alloys.

[0046] Optionally, refer to Figure 2The learning process of the pre-defined machine learning model includes preliminary preparation, dataset learning, and experimental verification. Preliminary preparation mainly consists of two parts: dataset preparation and machine learning model preparation. Dataset preparation includes data acquisition, construction of material descriptors, and selection of material descriptors. Specifically, it involves acquiring the composition, phase composition, UTS (Ultimate Tensile Strength), YS (Yield Strength), and δ phase of eutectic high-entropy alloy materials. The δ phase is an intermetallic compound or solid solution phase formed during solidification or heat treatment of the alloy. A material descriptor is a quantitative representation used to describe the characteristics or properties of a material, converting various properties, structures, and compositions of the material into numerical or vector forms that can be processed and analyzed by a computer. Material descriptor selection refers to removing redundant or irrelevant features from a large number of descriptors to improve model efficiency and interpretability. Machine learning model preparation involves building a machine learning model library according to the target requirements. Dataset learning refers to the process of a machine learning model working with a prepared dataset. Specifically, the prepared dataset is divided into K parts. Each time, one part is selected as the test set, and the remaining K-1 parts are used as the training set. This process is repeated K times to ensure that each sample appears in the test set at least once. This process is called K-fold cross-validation. During K-fold cross-validation, the accuracy or error rate is obtained by comparing the predicted values ​​and the actual values. The classification model with the highest accuracy or the regression model with the lowest error rate is selected. Experimental validation is then performed to evaluate the performance of each model in real-world environments and verify its effectiveness. This helps test the performance of machine learning models on new data and avoids overfitting to historical data.

[0047] Optionally, the machine learning computation is performed using Python in the Jupyter Notebook tool on the Anaconda Navigator software platform. Ultimately, it can achieve high-accuracy prediction of the FCC phase, BCC phase, and FCC+BCC phase composition in clad high-entropy alloys, with an accuracy exceeding 80%.

[0048] Optionally, the composition of the eutectic high-entropy alloy material can include a variety of elements, and the content of each element is within a certain reasonable range. The preset composition ratio range limits the search space of the preset machine learning model, avoiding unnecessary calculations and unreasonable combinations of components.

[0049] Optionally, a pre-set machine learning model can predict the phase structure and performance parameters corresponding to different component ratios based on the range of input component ratios and the patterns it has learned. This allows for the rapid acquisition of multiple possible results without conducting extensive practical experiments, thus improving the efficiency of materials research and development.

[0050] Step S130: If the predicted phase structure matches the target phase structure and the target performance parameters match the target performance parameters, determine the composition ratio of the eutectic high-entropy alloy material corresponding to the predicted phase structure and the target performance parameters as the target composition ratio.

[0051] In a feasible embodiment, when the predicted phase structure output by the model matches the target phase structure determined in step S110, and the target performance parameters match the target performance parameters, it indicates that the eutectic high-entropy alloy material with this composition ratio may meet the performance requirements of the bearing. The composition ratio corresponding to the predicted phase structure and target performance parameters that meet the matching conditions is determined as the target composition ratio. The target composition ratio is used for subsequent preparation of the eutectic high-entropy alloy material for bearings, so that the cladding layer has the required phase structure and performance parameters, thereby meeting the performance requirements of the bearing in practical applications.

[0052] Traditional experimental methods for determining the composition ratio of eutectic high-entropy alloys are time-consuming and costly. This implementation, by constructing and using a pre-defined machine learning model, can quickly predict the phase structure and performance parameters corresponding to different component combinations within a pre-defined composition ratio range, eliminating the need for extensive actual experiments, significantly shortening the R&D cycle and reducing costs. Regarding performance matching, the target phase structure and performance parameters are first determined, and then the matching composition ratio is screened through the model, accurately ensuring that the eutectic high-entropy alloy material meets the specific application requirements of bearings. In terms of model accuracy, the machine learning model, trained with extensive experimental data and materials science knowledge, employs K-fold cross-validation and experimental verification, achieving a high accuracy rate (over 80%) in predicting the phase composition of cladding-formed high-entropy alloys. The final determined target composition ratio is used to prepare bearing materials, ensuring the cladding layer possesses the required properties and meets the practical application needs of bearings.

[0053] Step S20: Using eutectic high-entropy alloy material as cladding material, a cladding layer is formed on the surface of the bearing substrate by a dual-beam cladding laser in a laser cladding device to produce the bearing.

[0054] In one feasible embodiment, a eutectic high-entropy alloy material is used as the cladding material, and a cladding layer with specific properties is formed on the surface of the bearing substrate by the action of a dual-beam cladding laser. This cladding layer can improve the surface properties of the bearing, such as increasing hardness, wear resistance, and corrosion resistance, thereby improving the service life and performance of the bearing.

[0055] Alternatively, laser cladding equipment is an advanced material processing device capable of cladding materials onto the substrate surface at extremely high speeds. Compared with traditional cladding methods, ultra-high-speed laser cladding can significantly improve cladding efficiency, reduce the heat-affected zone, and thus improve the quality of the cladding layer.

[0056] Optionally, using a dual-beam cladding laser offers several advantages. Firstly, the dual beam allows for more precise control of energy distribution during the cladding process, resulting in more uniform melting and spreading of the cladding material on the bearing substrate surface, thus improving the quality and uniformity of the cladding layer. Secondly, the dual beam can accelerate the cladding process, further enhancing production efficiency.

[0057] For example, traditional laser cladding has a dilution rate as high as 5% to 20%, and the mixing of matrix elements into the coating leads to performance degradation; while ultra-high speed laser cladding technology can make the dilution rate less than 1%, ensuring the purity of the coating composition, and is suitable for the preparation of high alloy materials on the surface of bearing steel.

[0058] Optionally, in traditional laser cladding, a high-power laser beam directly irradiates the substrate to form a molten pool (typically >1 mm deep). Simultaneously fed metal powder melts within the molten pool and achieves metallurgical bonding with the substrate. However, this process suffers from high heat input, leading to deep melting of the substrate due to the absorption of a large amount of heat, resulting in a wide heat-affected zone and a tendency to induce deformation and phase transformation. Ultra-high-speed laser cladding technology, on the other hand, achieves a fundamental paradigm shift by redesigning the interaction between the laser, powder, and substrate. Specifically, it includes a pre-melting mechanism during powder flight, where the laser beam heats the powder to a molten or semi-molten state before it reaches the substrate surface (melting during flight). Liquid droplets impacting the substrate form only a very shallow molten pool (0.01–0.1 mm). It also features ultra-low heat input, reducing substrate heat input by more than 90% (heat-affected zone <0.1 mm), and allowing substrate temperature to be controlled below 100°C, nearly achieving "cold processing." Furthermore, it possesses ultra-high-speed scanning capabilities, with scanning speeds 50–100 times faster than traditional cladding, significantly reducing heat accumulation effects.

[0059] In one feasible implementation, the laser cladding equipment includes a motion platform, a material source, and a laser source, wherein the laser source includes a first cladding light source and a second cladding light source.

[0060] Laser cladding equipment mainly consists of three parts: a motion platform, a material source, and a laser source.

[0061] The motion platform is used to support and drive the bearing substrate to be processed, moving it along a specific trajectory. By precisely controlling the movement of the motion platform, the cladding process can be carried out at a designated position on the surface of the bearing substrate, thereby achieving precise control over the cladding area and shape.

[0062] Optionally, the motion platform adopts a full servo gantry-type dual direct drive motion structure platform with motion control accuracy of ±0.001mm; it is equipped with a servo direct drive high-speed chuck, supports stepless speed change, and can efficiently achieve ultra-high-speed machining.

[0063] The material source is used to store and transport the eutectic high-entropy alloy material required for cladding. During the cladding process, the material source transports the eutectic high-entropy alloy material to the cladding area at a certain speed and quantity to ensure the formation of the cladding layer.

[0064] The laser source includes a first cladding source and a second cladding source, which perform different functions. The beam emitted by the first cladding source is used to pre-treat the surface of the bearing substrate, while the beam emitted by the second cladding source is used to clad the eutectic high-entropy alloy material onto the surface of the bearing substrate.

[0065] The steps of using a eutectic high-entropy alloy material as the cladding material and forming a cladding layer on the surface of the bearing substrate by a dual-beam cladding laser in a laser cladding device include: Step S210: Control the bearing base on the motion platform to move along a preset trajectory; In one feasible embodiment, before performing the cladding operation, the motion trajectory of the motion platform needs to be pre-planned based on the shape and size of the bearing substrate and the design requirements of the cladding layer. During the cladding process, the control system precisely controls the motion platform, causing the bearing substrate to move along the preset trajectory. For example, if cladding is required on the circumferential surface of the bearing substrate, the motion platform may drive the bearing substrate to rotate; if cladding is performed on a plane, it may move in a straight line or curve. This ensures that the cladding layer can uniformly and accurately cover the target surface of the bearing substrate.

[0066] Step S220: Control the material source to deliver eutectic high-entropy alloy material; In one feasible embodiment, the material source is typically equipped with a dedicated conveying device, such as a powder feeder. During the cladding process, the control system precisely controls the speed and flow rate of the eutectic high-entropy alloy material conveyed by the material source according to the requirements of the cladding process. Appropriate material conveying speed and flow rate are crucial for forming a high-quality cladding layer. If the conveying speed is too fast, it may result in uneven cladding layer thickness or incomplete fusion; if the conveying speed is too slow, a continuous and complete cladding layer may not be formed.

[0067] Step S230: Control the first cladding light source to emit the first cladding beam to pre-treat the surface of the bearing substrate to form a microtexture; In one feasible embodiment, the first cladding beam emitted by the first cladding light source has specific energy and parameters. While the bearing substrate moves along a preset trajectory, the first cladding beam irradiates the surface of the bearing substrate, pre-treating it. The pre-treatment includes forming a micron-scale molten pit structure, or microtexture, on the surface of the bearing substrate using a laser. The microtexture enhances the coating adhesion through an "anchoring effect," effectively improving bonding strength and directly replacing traditional processes such as sandblasting. Furthermore, the pre-treatment can preheat the substrate surface, reducing thermal stress during the cladding process and lowering the likelihood of defects such as cracks.

[0068] Step S240: Control the second cladding light source to emit a second cladding beam, and clad the eutectic high-entropy alloy material onto the surface of the bearing substrate to form a cladding layer.

[0069] In one feasible embodiment, after the first cladding light source completes the pretreatment of the bearing substrate surface, the second cladding light source emits a second cladding beam. The second cladding beam has sufficient energy to rapidly heat the eutectic high-entropy alloy material to a molten state and metallurgically bond it with the pretreated bearing substrate surface. As the second cladding beam moves, the molten material gradually solidifies, forming a continuous cladding layer.

[0070] This embodiment can simultaneously achieve surface pretreatment of the bearing substrate and ultra-high-speed laser cladding on the preheated workpiece surface with surface microstructure by using dual light sources, thus completing the cladding process of the workpiece in one go and accelerating the preparation efficiency.

[0071] For example, refer to Figure 3 In the dual-beam cladding laser, the first cladding beam emitted by the first cladding source forms a rectangular spot, while the second cladding beam emitted by the second cladding source forms a circular spot. The dual-beam cladding laser can be controlled collaboratively by a control module, and the relative positions of the spots can be adjusted arbitrarily to meet the needs of different processing techniques and achieve linked processing. Figure 3 Figures a, b, c, and d show the light spots formed by the first and second cladding beams at different positions on the surface of the bearing substrate, respectively.

[0072] For example, in the core configuration of the dual-light source, a Chuangxin 600-core 6000-watt multimode laser is used, paired with a RayTools 6000-watt transmissive laser cladding head. The spot size is infinitely adjustable and equipped with 6 nozzles, serving as the first cladding light source. A Chuangxin 200-core 2000-watt multimode laser is used, configured with a direct water-cooled copper reflective laser heat treatment head, forming a rectangular spot through integration and shaping, serving as the second cladding light source.

[0073] Optionally, the laser cladding equipment is also equipped with a three-cesium closed-loop temperature measuring instrument to achieve coaxial real-time precise temperature control. It is also equipped with a FLIR (Forward Looking Infrared) thermal imager, which can perform real-time precise temperature measurement and data acquisition of the laser molten pool, ensuring a stable and controllable processing process.

[0074] In this embodiment, the system employs a combined design of a motion platform, a material source, and a laser source, enabling precise control of the cladding process. The motion platform drives the bearing substrate along a preset trajectory, ensuring that the cladding layer uniformly and accurately covers the target surface, meeting the cladding requirements for different shapes and sizes. The material source precisely delivers eutectic high-entropy alloy material, with appropriate delivery speed and flow rate ensuring the formation of a high-quality cladding layer. The dual-source design of the laser source involves the first cladding source emitting a beam that pre-treats the substrate surface, forming a microtexture. This "anchoring effect" enhances the coating's adhesion and improves bonding strength, replacing traditional sandblasting. It also preheats the substrate, reducing cladding thermal stress and minimizing defects such as cracks. The second cladding source clads the eutectic high-entropy alloy material onto the substrate surface, utilizing the superior properties of the eutectic high-entropy alloy to improve the bearing's hardness, wear resistance, and corrosion resistance, extending bearing life and reducing equipment maintenance costs.

[0075] In one feasible embodiment, the system further includes a laser polishing apparatus, and after the step of forming a cladding layer on the bearing substrate surface by a dual-beam cladding laser in the laser cladding apparatus, it further includes: The surface of the cladding layer is polished using a dual-beam polishing laser from a laser polishing equipment, resulting in a surface roughness Ra < 0.1 μm after polishing.

[0076] In one feasible embodiment, the system is also equipped with a laser polishing device. The laser polishing device is used to further process the surface of the cladding layer, improving its quality. After the cladding layer is successfully formed on the bearing substrate surface using the dual-beam cladding laser of the laser cladding device, the surface of the cladding layer is then polished using the laser polishing device. This sequence is logical because the subsequent polishing operation can only be performed on the surface of the cladding layer after it has been formed.

[0077] Laser polishing equipment uses a dual-beam polishing laser. The dual-beam design is used to improve polishing efficiency, enhance polishing effect, or achieve more precise polishing control. Through the synergistic effect of the two beams, the surface of the cladding layer can be heated and melted more evenly, causing the material in the microscopic protrusions of the surface to flow at high temperature and fill the depressions, thereby achieving the purpose of smoothing the surface.

[0078] In one feasible embodiment, after processing with laser polishing equipment, the surface roughness Ra of the cladding layer is less than 0.1 μm. The smaller the surface roughness, the smoother the surface. Controlling the surface roughness of the cladding layer within the range of Ra < 0.1 μm means that the cladding layer surface has achieved a high degree of smoothness. Such a smooth surface can reduce frictional resistance, lower energy loss during bearing operation; improve surface corrosion resistance, as a smooth surface is less prone to accumulating dirt and moisture, reducing the possibility of corrosion; and also improve the sealing performance of the bearing, preventing external impurities from entering the bearing, thereby extending the bearing's service life.

[0079] Optionally, the laser polishing equipment adopts a dual-laser beam synergistic structure, consisting of a high-precision three-dimensional galvanometer, an XY-axis moving axis, and a cradle-type rotary table to achieve five-axis CNC machining. It can precisely polish free-form surfaces with a processing control accuracy of ±0.001mm. Equipped with a steady-state auxiliary magnetic field and combined with flat-top laser shaping technology, it can flexibly adapt to the high-efficiency polishing needs of curved surfaces of different materials.

[0080] In one feasible implementation, the dual-beam polishing laser includes a first polishing beam and a second polishing beam, wherein the first polishing beam includes a continuous laser for rough polishing; and the second polishing beam includes a pulsed laser for mirror polishing.

[0081] In one feasible embodiment, the dual-beam polishing laser consists of a first polishing beam and a second polishing beam. These two beams have different characteristics and functions, and work together to complete the high-quality polishing process of the cladding layer surface.

[0082] Optionally, continuous laser refers to a type of laser that continuously outputs stable laser energy over a period of time. Its output laser power is relatively stable, enabling it to maintain energy input to the cladding layer surface for a relatively long period. Rough polishing primarily involves preliminary leveling of the cladding layer surface. After the cladding process, the cladding layer surface may have significant microscopic defects such as undulations, protrusions, or depressions. The energy of the continuous laser can rapidly heat these larger protrusions to a molten state. Due to the fluidity of the material, the molten material flows towards the depressions, thereby reducing the surface unevenness and surface roughness to some extent. This preliminary leveling lays the foundation for subsequent fine polishing.

[0083] Alternatively, a pulsed laser is a laser that outputs energy in pulses. Its characteristic is the release of extremely high energy in a short time, with no energy output during the pulse intervals. Pulsed lasers are characterized by high energy density and short action time. After rough polishing, larger defects on the cladding layer surface have been improved, but some minor unevenness still exists. The high energy density of the pulsed laser can precisely target these minor defects. The pulsed laser can bring the molten metal surface to a laminar flow state, accurately filling a small amount of molten metal into the depressions, further reducing the surface roughness of the cladding layer, and ultimately achieving a precision polishing effect. Due to the short pulse duration, the thermal impact on surrounding materials is minimal, avoiding the generation of new defects due to overheating. Through multiple pulsed laser actions, the surface roughness of the cladding layer can be gradually reduced to an extremely low level, ultimately achieving a mirror-like effect and meeting the requirement of surface roughness Ra < 0.1 μm.

[0084] Optionally, refer to Figure 4 The coarse polishing with the first polishing beam and the mirror polishing with the second polishing beam are a gradual process. Figure 4 Figure a shows two lines formed by the first and second polishing beams during rapid polishing of the cladding layer on the bearing. Figure 4 Figure b shows the laser polishing process. First, a continuous laser is used to perform rough polishing on the original 3D morphology of the bearing cladding layer, quickly removing larger defects and peaks on the cladding layer surface. This redistributes the surface undulations and peaks, improving the overall surface smoothness and forming a smoother polished 3D morphology. Then, a pulsed laser is used for mirror polishing to refine the surface, further reducing surface roughness and enabling the cladding layer surface to reach a high-quality surface finish standard. Figure 4 The red dashed line in Figure b represents the area where the polishing laser beam interacts with the cladding material. This dual-beam polishing method fully leverages the advantages of both continuous and pulsed lasers, improving polishing efficiency and quality.

[0085] In this embodiment, a dual-beam polishing laser is used to treat the surface of the cladding layer, controlling the surface roughness to Ra < 0.1 μm, achieving a high degree of surface smoothness, reducing frictional resistance during bearing operation, lowering energy loss, and improving energy utilization efficiency. It also enhances surface corrosion resistance; the smooth surface is less prone to accumulating dirt and moisture, reducing the possibility of corrosion and extending bearing life. The dual beams work in tandem: continuous laser coarse polishing removes larger defects, laying the foundation for fine processing, while pulsed laser mirror polishing precisely handles minor unevenness, fully leveraging the advantages of both to improve polishing efficiency and quality. The laser polishing equipment uses five-axis CNC machining, combined with a steady-state auxiliary magnetic field and flat-top laser shaping technology, enabling precise polishing of free-form surfaces and flexibly adapting to the high-efficiency polishing needs of different material surfaces.

[0086] In one feasible embodiment, a reinforcing layer is formed on the surface of the cladding layer during the polishing process.

[0087] In one feasible embodiment, when polishing the cladding layer surface using a dual-beam polishing laser (continuous laser rough polishing and pulsed laser mirror polishing), the laser carries a large amount of energy and acts on the cladding layer surface. The continuous heating of the continuous laser melts and flows the larger protrusions on the cladding layer surface, while the extremely high energy released by the pulsed laser in a short time acts precisely on tiny defects. This energy input causes changes in the microstructure of the cladding layer surface material. For example, it may promote grain refinement, with larger grains splitting into smaller grains during high temperature and rapid cooling, thereby increasing the grain boundary area. Grain boundaries can hinder dislocation movement, improving the strength and hardness of the material. The high temperature of the laser also accelerates the diffusion of elements on the cladding layer surface, allowing for thorough mixing between different elements. Some alloying elements may dissolve into the base metal, forming a solid solution. According to the principle of solid solution strengthening, the presence of solute atoms distorts the crystal lattice, thereby improving the material's resistance to deformation, further enhancing the material's strength and hardness, and contributing to the formation of a strengthening layer.

[0088] Optionally, the reinforcing layer has higher hardness and strength. When the cladding surface rubs against other components, the reinforcing layer can better resist wear, reduce material loss, and extend the service life of the cladding layer. For example, in the actual operation of bearings, the reinforcing layer can reduce the wear rate between the bearing and components such as the journal, ensuring the stable operation of the bearing.

[0089] Optionally, the reinforced layer has a denser structure, which can effectively prevent the intrusion of external corrosive media (such as oxygen, moisture, chemicals, etc.), thereby improving the corrosion resistance of the cladding layer surface.

[0090] This embodiment achieves effective temperature field control through reasonable process parameter setting during laser polishing, and performs a heat treatment process on the cladding layer formed by the high-entropy alloy material. During the rapid cooling process of the cladding layer material, the grains of the cladding layer can be refined and the dispersed phase can be precipitated. The resulting strengthening layer improves the mechanical properties and tribological properties of the bearing.

[0091] In one feasible embodiment, the thickness of the cladding layer is 0.01 mm to 0.2 mm.

[0092] Optionally, the thickness of the cladding layer can be 0.01mm, 0.02mm, 0.03mm, 0.04mm, 0.05mm, 0.06mm, 0.07mm, 0.08mm, 0.09mm, 0.1mm, 0.01mm, 0.12mm, 0.13mm, 0.14mm, 0.15mm, 0.16mm, 0.17mm, 0.18mm, 0.19mm, 0.2mm, etc.

[0093] Optionally, the main function of the cladding layer is to improve the surface properties of the substrate material, such as increasing hardness, wear resistance, and corrosion resistance. If the cladding layer thickness is too small, these performance improvements may not be effectively achieved. If the cladding layer thickness is too large, it will increase material costs and processing time; furthermore, an excessively thick cladding layer may generate significant internal stress, leading to defects such as cracks and peeling, which ultimately affect its performance and service life. A cladding layer thickness in the range of 0.01mm to 0.2mm makes it easier to achieve a stable cladding process. Thinner cladding layers are relatively easier to control in terms of laser energy input and cladding material, ensuring good bonding strength between the cladding layer and the substrate. When the cladding layer thickness is too large, problems such as uneven cladding and porosity may occur, affecting the quality and performance of the cladding layer.

[0094] In one feasible embodiment, refer to Figure 5 The system sequentially achieves an efficient and stable fabrication process for high-performance bearings through material design, cladding processing, laser polishing, and final bearing performance verification. Eutectic high-entropy alloys, through compositional design and the use of machine learning models to enhance the relationship between mechanism and performance during the construction process, provide a specialized material with both high strength and toughness and a good process window for the cladding process, meeting the extreme operating conditions of bearings from the outset. Secondly, dual-beam ultra-high-speed cladding, utilizing the pre-processing of the first cladding beam and the precise cladding formation of the second cladding beam, enables the formation of a cladding layer of eutectic high-entropy alloy on the bearing substrate. Finally, dual-beam laser polishing cleans, remelts, and refines the surface of the cladding layer. The first polishing beam is used for rough polishing to reduce surface roughness, while the second laser polishing beam is used for fine mirror polishing, forming a reinforcing layer. The entire process forms a closed-loop feedback loop, where surface performance data drives iterative optimization of materials and processes, systematically overcoming the comprehensive bottlenecks in materials, forming, and surface integrity of high-end bearings, achieving a comprehensive improvement in reliability, lifespan, and performance.

[0095] This embodiment identifies a eutectic high-entropy alloy material for bearings. Eutectic high-entropy alloys possess excellent properties, such as high strength, high hardness, good wear resistance, and corrosion resistance, providing a foundation for preparing high-performance bearing cladding layers. Using this eutectic high-entropy alloy material as the cladding material, a cladding layer is formed on the bearing substrate surface using a dual-beam cladding laser in a laser cladding device, thus producing the bearing. Compared to a single beam, using a dual-beam cladding laser allows for more uniform heating and melting of the cladding material, resulting in better fusion with the bearing substrate, reducing defects such as porosity and cracks in the cladding layer, and improving the quality and stability of the cladding layer. Simultaneously, the dual-beam design accelerates the cladding speed, allowing for more cladding work to be completed within the same timeframe, significantly improving preparation efficiency. Therefore, this embodiment achieves an efficient and stable preparation process for the cladding layer of high-performance bearings.

[0096] The second aspect of this application provides a laser manufacturing system for bearings, referring to... Figure 6 and Figure 7 The system includes: Laser cladding equipment 10 is used to form a cladding layer on the surface of a bearing substrate; The control module 20 is used to determine the eutectic high-entropy alloy material used to manufacture the bearing; the eutectic high-entropy alloy material is used as the cladding material, and a cladding layer is formed on the surface of the bearing substrate by a dual-beam cladding laser in the laser cladding equipment to produce the bearing.

[0097] Optionally, an integrated solution based on the Xstudio control unit was adopted, enabling customized development of integrated units including motion units, lasers, powder feeding, and cooling gases. This solution shows great promise in technologies such as ultra-high-speed laser cladding, internal hole cladding, red-blue composite cladding, and laser heat treatment.

[0098] For example, refer to Figure 7 The laser cladding equipment 10 includes a laser source 110, a motion platform 120, a material source 130, and a chiller 140. The laser source 110 includes a first cladding light source 111 and a second cladding light source 112. The first cladding light source 111 is used to emit a first cladding beam for pre-treating the cladding material. The second cladding light source 112 is used to emit a second cladding beam for forming a cladding layer on the surface of the bearing after cladding the cladding material.

[0099] In one feasible embodiment, refer to Figure 6 The system also includes a laser polishing device 30, which is used to polish the surface of the cladding layer using a dual-beam polishing laser.

[0100] The third aspect of this application provides a bearing manufactured by the laser manufacturing method of the bearing described in the above embodiments.

[0101] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the patent protection scope of this application.

Claims

1. A laser manufacturing method for a bearing, characterized in that, A laser manufacturing system for bearings, the system including laser cladding equipment, the method comprising: Determine the eutectic high-entropy alloy material for bearings; The eutectic high-entropy alloy material is used as the cladding material, and a cladding layer is formed on the surface of the bearing substrate by a dual-beam cladding laser in the laser cladding equipment to produce the bearing.

2. The laser manufacturing method for bearings as described in claim 1, characterized in that, The laser cladding equipment includes a motion platform, a material source, and a laser source. The laser source includes a first cladding light source and a second cladding light source. The step of using the eutectic high-entropy alloy material as the cladding material and forming a cladding layer on the bearing substrate surface using a dual-beam cladding laser in the laser cladding equipment includes: Control the bearing base on the motion platform to move along a preset trajectory; The material source is controlled to deliver the eutectic high-entropy alloy material; The first cladding light source is controlled to emit a first cladding beam, which pre-treats the surface of the bearing substrate to form a microtexture. The second cladding light source is controlled to emit a second cladding beam, which clads the eutectic high-entropy alloy material onto the surface of the bearing substrate to form the cladding layer.

3. The laser manufacturing method for bearings as described in claim 1, characterized in that, The system further includes a laser polishing device, and after the step of forming a cladding layer on the bearing substrate surface using a dual-beam cladding laser in the laser cladding device, it further includes: The surface of the cladding layer is polished using a dual-beam polishing laser from the laser polishing equipment, wherein the surface roughness Ra of the cladding layer after polishing is less than 0.1 μm.

4. The laser manufacturing method for bearings as described in claim 3, characterized in that, The dual-beam polishing laser includes a first polishing beam and a second polishing beam, wherein the first polishing beam includes a continuous laser for rough polishing; and the second polishing beam includes a pulsed laser for mirror polishing.

5. The manufacturing method as described in claim 4, characterized in that, During the polishing process, a reinforcing layer is formed on the surface of the cladding layer.

6. The manufacturing method as described in claim 1, characterized in that, The thickness of the cladding layer is 0.01 mm to 0.2 mm.

7. The laser manufacturing method for bearings as described in claim 1, characterized in that, The step of determining the eutectic high-entropy alloy material for the bearing includes: Determine the target phase structure and target performance parameters of the eutectic high-entropy alloy material; Based on a preset machine learning model, within a preset composition ratio range of the eutectic high-entropy alloy material, the predicted phase structure and target performance parameters are output. When the predicted phase structure matches the target phase structure and the target performance parameters match the target performance parameters, the composition ratio of the eutectic high-entropy alloy material corresponding to the predicted phase structure and the target performance parameters is determined as the target composition ratio.

8. A laser manufacturing system for bearings, characterized in that, The system includes: Laser cladding equipment is used to form a cladding layer on the surface of a bearing substrate; The control module is used to determine the eutectic high-entropy alloy material for manufacturing the bearing; the eutectic high-entropy alloy material is used as the cladding material, and a cladding layer is formed on the surface of the bearing substrate by the dual-beam cladding laser in the laser cladding equipment to obtain the bearing.

9. The laser manufacturing system for bearings as described in claim 8, characterized in that, The system also includes a laser polishing device for polishing the surface of the cladding layer using a dual-beam polishing laser.

10. A bearing manufactured by the laser manufacturing method of any one of claims 1 to 7.

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