Cored Wire for Hybrid Laser Cladding of Track Sealing Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing track sealing systems in machines have poor corrosion resistance, leading to accelerated wear in environments other than dry climates, reducing the lifespan of these components.
Innovation Solution
A cored wire with a core powder composition, including specific weight percentages of elements like carbon, manganese, chromium, titanium, vanadium, boron, phosphorus, and sulfur, is used in a hybrid laser cladding process to deposit a layer on machine components, enhancing both wear and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard, strong materials such as alloyed steels are used for track sealing systems, then wear resistance is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by creating a multi-layer overlay structure consisting of a base alloyed steel layer providing wear resistance and a corrosion-resistant layer containing chromium, nickel, and other alloying elements. This composite structure allows both wear resistance and corrosion resistance to coexist, resolving the technical contradiction between these two properties.
Solution Approach 2:
The patent implements local quality by applying different material compositions to different regions or layers of the track sealing system. The overlay compound contains spatially distributed alloying elements with specific concentrations (e.g., chromium 2-10%, nickel 1-5%) that are tailored to provide corrosion resistance at the surface while maintaining wear resistance in the bulk material.
2Reliability
If composite overlays are applied to improve corrosion resistance, then corrosion resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into a single manufacturing process by combining the application of wear-resistant and corrosion-resistant layers in one hybrid laser cladding operation. The overlay compound is applied as a single mixture containing both wear-resistant particles and corrosion-resistant alloying elements, which are then simultaneously processed to form an integrated protective layer, reducing manufacturing complexity compared to separate coating operations.
Solution Approach 2:
The patent uses parameter changes in the laser cladding process (such as laser power, scanning speed, and powder feed rate) to control the microstructure and composition of the overlay layer. By adjusting these parameters, the process achieves optimal balance between wear resistance and corrosion resistance while maintaining manufacturing efficiency, thus reducing the practical complexity despite the multi-functional requirements.
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 results in a two to three fold improvement in wear resistance and improved corrosion resistance for machine components, specifically the track sealing systems, extending their lifespan.
Implementation Method 1
hybrid laser cladding process
Implementation Method 2
melting a cored wire on to a substrate with hybrid laser cladding
Implementation Method 3
form a solid layer bonded to the substrate
Data Source
AI summary
A cored wire for hybrid laser cladding includes a hollow metal sheath and a core powder composition. The core powder can include, by weight percent: carbon from about 0.8% to about 1.2%, manganese from about 1% to about 1.4%, silicon from about 0.8% to about 1%, chromium from about 22% to about 30%, titanium from about 0.5% to about 2%, vanadium from about 0.5% to about 2%, boron from about 0.8% to about 1.2%, phosphorus from 0% to about 0.04%, and sulfur from 0% to about 0.03%, the balance of the core powder composition being substantially iron. Components and methods using the cored wire are also disclosed.