Bearing Ring Surface Cladding for Cost-Effective Remanufacturing
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Solution Overview
Problem
The high cost and material limitations of producing large rolling or plain bearing rings, especially those over 500 mm in diameter, and the limited remanufacturing capabilities due to dimensional constraints, hinder their widespread use and efficiency.
Innovation Solution
A method involving Directed Energy Deposition (DED) techniques, such as laser cladding, is used to apply a high-performance steel surface on metallic ring members, allowing for thicker material layers and improved surface hardness, enabling cost-effective production and remanufacturing of bearing rings with tailored material properties for demanding applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stainless steel is used for bearing rings to provide corrosion resistance, then corrosion resistance is improved, but material cost increases significantly
Solution Approach 1:
The patent applies a stainless steel layer only to the load-bearing surfaces of the bearing ring through DED process, rather than using stainless steel for the entire ring. This provides corrosion resistance where it is most needed (at the surfaces exposed to environment) while using cheaper carbon steel for the bulk material, thereby reducing overall material cost while maintaining reliability.
Solution Approach 2:
The patent creates a composite structure with a carbon steel substrate and a stainless steel surface layer applied via DED. This composite approach combines the advantages of both materials: the low cost and structural strength of carbon steel with the corrosion resistance and surface properties of stainless steel, achieving cost-effective corrosion protection.
2Reliability
If DED operation is used to apply steel surface on metallic ring member, then service life and performance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical surface treatment methods (such as mechanical coating or physical vapor deposition) with Directed Energy Deposition, which uses thermal energy (laser or electron beam) to melt and deposit material. This substitution enables thicker layers to be applied with better metallurgical bonding to the substrate, improving service life despite increased manufacturing complexity.
3Ease of repair
If traditional machining is used to remove damaged surfaces for remanufacturing, then bearing rings can be reused, but material removal is limited to very thin layers
Solution Approach 1:
Instead of removing material through machining to restore the bearing surface, the patent inverts the approach by adding material through DED process. This allows thick layers of new material to be deposited over damaged surfaces, completely replacing the damaged raceway while maintaining the original bearing ring dimensions, thereby enabling remanufacturing of bearings with significant damage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in bearing rings with increased service life, improved performance, and enhanced remanufacturing possibilities, while reducing material costs and accommodating various industrial applications, including pulp and paper, wind turbines, and mining industries.
Implementation Method 1
applying a load carrying surface onto the metallic ring member by use of a steel wire Directed Energy Deposition (DED) operation and/or a steel metal powder DED operation
Data Source
AI summary
A method for manufacturing a rolling or plain bearing ring includes providing a metallic ring member and applying a load carrying surface onto the metallic ring member by use of a steel wire Directed Energy Deposition (DED) operation and/or a steel metal powder DED operation. Preferably, the steel wire and/or the steel metal powder includes 0.10-0.50 wt % of carbon and 0.50-1.20 wt % of boron.