Laser-Heated Boride Composite Surface for Wear Resistance

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Solution Overview

Problem

Existing metal alloys like titanium, aluminum, and steels lack sufficient wear and corrosion resistance for dynamic machinery applications, and current surface treatment techniques often result in distortion, reduced smoothness, and delamination.

Innovation Solution

A method involving the disposal of a precursor material, such as titanium diboride or boron, on a substrate followed by heating in the presence of an oxidation preventative to form a reinforced composite structure, which interjoins with the substrate, enhancing wear and corrosion resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If plasma spraying, sputtering, or plating techniques are used to add a wear resistance layer to metal substrates, then wear and corrosion resistance is improved, but substrate geometry distortion occurs, surface smoothness is reduced, and layer delamination happens

Engineering Contradiction:

Improvewear and corrosion resistanceVSAvoidsubstrate geometry and surface smoothness

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention changes the fundamental parameters of the surface treatment process by using laser heating to form a eutectic mixture of metal and ceramic particles embedded in a metal matrix. This approach transforms the process from cold spraying/deposition to thermal processing, achieving wear-resistant surfaces without the geometric distortion and delamination problems of conventional techniques

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite material structure consisting of ceramic particles (alumina, silica, boron carbide, etc.) embedded in a metal matrix (aluminum, aluminum alloy, or steel). This composite structure provides both the wear/corrosion resistance of ceramics and the toughness of metals, while being integrated into the substrate without delamination

Inventive Principle:

Principle #40Composite materials

2Strength

If surface hardening techniques like nitriding and carbiding are applied to steels, then strength is improved, but wear resistance remains inadequate for many applications

Engineering Contradiction:

Improvesteel strengthVSAvoidwear resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

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

The method effectively creates a composite structure with improved hardness, high-temperature strength, and wear and corrosion resistance without altering the bulk properties of the substrate, providing a durable and long-lasting surface modification.

Implementation Method 1

heating the precursor material and the at least a portion of the substrate in the presence of an oxidation preventative until at least a portion of the precursor material forms a reinforced material that is interjoined with the at least a portion of a substrate

Methodology Applied

Scientific EffectInterjoining: Welding

Implementation Method 2

heating the precursor material and the at least a portion of the substrate in the presence of an oxidation preventative

Methodology Applied

Scientific EffectOxidation prevention: Oxidation

Data Source

PatentUS9682531B2Toughened and corrosion- and wear-resistant composite structures and fabrication methods thereof

Publication Date: 2017.06.20 CONSOLIDATED NUCLEAR SECURITY LLC

AI summary

Composite structures having a reinforced material interjoined with a substrate, wherein the reinforced material comprises a compound selected from the group consisting of titanium monoboride, titanium diboride, and combinations thereof.