Cladded Tool Coating With Graded Hard Particle Distribution

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Solution Overview

Problem

Existing cladding technologies face challenges in effectively bonding dissimilar metals with high wear resistance and uniform distribution of hard phase particles on tool surfaces, particularly in creating robust cutting edges for tools like saw blades and multi-tool blades.

Innovation Solution

A method involving a laser cladding system with a distributor and energy source, using agglomerated particles between 30 and 100 microns, and hard phase particles to form a bonded layer with a higher concentration of hard phase particles further from the substrate, enhancing wear resistance and flowability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional cladding technologies are used to bond dissimilar metals, then metallurgical bonding is achieved, but uniform distribution of hard phase particles is not achieved

Engineering Contradiction:

Improveuniform distribution of hard phase particlesVSAvoidwear resistance

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies local quality by creating a non-uniform distribution of hard phase particles within the cladded layer, specifically concentrating them in the intermediate zone between the substrate and the outer surface. This localized concentration of hard particles in specific regions (further from the substrate) provides enhanced wear resistance at the cutting edge while maintaining proper bonding at the substrate interface, resolving the contradiction between uniform distribution and wear resistance.

Inventive Principle:

Principle #3Local quality

2Reliability

If high concentration of hard phase particles is used, then wear resistance is improved, but surface porosity increases

Engineering Contradiction:

Improvewear resistanceVSAvoidsurface porosity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent resolves this contradiction by applying local quality through spatial differentiation of hard phase particle concentration. High concentrations of hard particles are placed in the intermediate zone (further from the substrate) where wear resistance is most needed for cutting edges, while the region adjacent to the substrate maintains lower porosity for proper bonding. This localized placement eliminates the trade-off between hard particle concentration and porosity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs parameter changes by varying the concentration of hard phase particles as a function of depth from the substrate. The concentration increases from the substrate interface toward the intermediate zone, creating a gradient structure. This parameter variation allows high hard particle content (for wear resistance) in critical regions while maintaining lower porosity near the substrate, resolving the contradiction between these two parameters.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If traditional laser cladding with fine particles is used, then bonding is achieved, but flowability and particle distribution are compromised

Engineering Contradiction:

ImproveflowabilityVSAvoidparticle distribution

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by utilizing agglomerated particles with diameters between 30 and 100 microns, which is a significant size increase from conventional fine cladding particles. This parameter change in particle size improves flowability and handling characteristics of the particulate material. The agglomerated structure maintains adequate flow properties while the laser processing parameters are adjusted to achieve proper distribution and bonding, resolving the contradiction between flowability and particle distribution.

Inventive Principle:

Principle #35Parameter changes

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 achieves improved wear resistance and reduced surface porosity by forming a metallurgically bonded wear-resistant coating layer with increased hard phase particle coverage, particularly beneficial for cutting edges with high teeth per inch (TPI) ratios.

Implementation Method 1

activating the energy source to produce a beam spot on the particulate material, the substrate, or both and at least partially melting the particulate material, the substrate, or both with the beam spot

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

at least partially melting the particulate material, the substrate, or both with the beam spot to form a bonded layer

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

the powder material is bonded to the material of the article... to form a bonded layer of particulate material on the substrate

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS20220288688A1Cladded tool and method of making a cladded tool

Publication Date: 2022.09.15 MILWAUKEE ELECTRIC TOOL CORP

AI summary

A method of creating a cladded tool with a distributor including a feed mechanism and an energy source. The method includes providing a substrate and distributing particulate material from the feed mechanism onto the substrate. The particulate material includes agglomerated particles with diameters between 30 and 100 microns. The method also includes activating the energy source to produce a beam spot on the particulate material, the substrate, or both and at least partially melting the particulate material, the substrate, or both with the beam spot to form a bonded layer of particulate material on the substrate.