Layered Bearing Components Using Cold Spray for Custom Dimensions
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Solution Overview
Problem
The manufacturing of bearing components is limited by the availability of pre-manufactured blanks, restricting the production of components with unique dimensions and materials, making it costly to create individualized bearing components with specific properties.
Innovation Solution
The use of a cold-spray method to build up bearing components layer-by-layer using metallic powders, allowing for the creation of components with arbitrary dimensions and varying material compositions, enabling flexible and precise manufacturing without the limitations of standard sizes and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If premanufactured blanks are used for manufacturing bearing components, then the manufacturing process is simple and efficient, but the dimensions and materials are restricted to standard ranges
Solution Approach 1:
The patent applies parameter changes by transitioning from discrete standard-sized blanks to continuous variable-dimensional components manufactured through additive layer-by-layer construction, enabling arbitrary dimensions and material compositions while maintaining manufacturing efficiency
Solution Approach 2:
The patent introduces a new manufacturing dimension by building components layer-by-layer in three-dimensional space, allowing components to be constructed from powder material deposited in controlled layers, thereby achieving custom dimensions and material properties without relying on pre-manufactured blanks
2Adaptability or versatility
If individual bearing components with unique dimensions are manufactured from premanufactured blanks, then customized dimensions can be achieved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent enables cost-effective dimensional customization by constructing components layer-by-layer from powder material, eliminating the need to source or modify expensive pre-manufactured blanks for each unique dimension requirement
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from subtractive or formative processing of fixed blanks to additive construction from powder, allowing arbitrary dimensions and material compositions to be achieved economically through controlled layer deposition
3Ease of manufacture
If bearing components are manufactured using conventional methods, then standard materials can be used, but customization of material composition is hardly possible
Solution Approach 1:
The patent applies composite materials by enabling the use of powder forms of various materials including metals, ceramics, and polymers, either individually or in combination, allowing customized material compositions to be deposited layer-by-layer according to specific application requirements
Solution Approach 2:
The patent changes the material state parameter from solid blanks to powder form, and changes the material composition parameter from fixed standard materials to customizable formulations, enabling selective deposition of different materials and compositions through the additive manufacturing process
4Strength
If thermal methods are used for manufacturing bearing components, then material bonding is strong, but thermal stress and deformation occur
Solution Approach 1:
The patent changes the temperature parameter from high-thermal-process to low- or no-thermal-process, using cold spray or room temperature bonding methods to deposit layers, thereby achieving sufficient layer adhesion without inducing thermal stress or deformation in the component
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 enables the production of bearing components with customized dimensions, material properties, and porosity, ensuring mechanical stability and minimizing thermal stress, while allowing for post-processing to achieve precise final dimensions and surface quality, thus addressing the limitations of traditional manufacturing methods.
Implementation Method 1
the bearing component is not manufactured to size from a blank, but rather is built up by a plurality of layers that are applied one onto another using a cold-spray method
Implementation Method 2
a preheated gas jet is generated into which a predominantly metallic powder is fed, which, however, is not melted
Data Source
AI summary
Disclosed is a bearing component (1) that is comprised of a plurality of radially and/or axially extending layers (2, 4, 6), wherein the plurality of layers (2, 4, 6) are applied one atop the other using a cold-spray method.