Gradient Metallic Structure for Wear Resistance

Solution Overview

Problem

Conventional materials face challenges in achieving a balance between strength, plasticity, wear resistance, and corrosion resistance, particularly under severe environmental conditions, where existing alloys often sacrifice plasticity for increased strength and wear resistance.

Innovation Solution

A multilayer gradient structural alloy is fabricated by depositing an amorphous metal layer on a substrate with a crystalline structure featuring a gradient grain size, processed using surface mechanical attrition treatment and magnetron sputtering, resulting in enhanced mechanical properties and corrosion resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional alloys are strengthened to improve wear resistance, then wear resistance is improved, but plasticity deteriorates

Engineering Contradiction:

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The invention applies different structural characteristics to different regions of the metal layer. The bottom portion contains crystalline structures with larger grain sizes for ductility, while the top portion contains amorphous structures for hardness and wear resistance. This local differentiation allows each region to exhibit its optimal properties without compromising the other.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention creates a composite structure within the metal layer by combining crystalline and amorphous phases. The crystalline phase provides ductility and toughness, while the amorphous phase provides hardness and wear resistance. The composite nature of this multi-phase structure enables simultaneous achievement of plasticity and wear resistance that cannot be obtained in conventional single-phase alloys.

Inventive Principle:

Principle #40Composite materials

2Strength

If metal layer is deposited on substrate, then wear resistance is improved, but surface indentation and cracking increase

Engineering Contradiction:

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention prepares the substrate surface beforehand by creating a gradient crystalline structure with varying grain sizes before depositing the amorphous metal layer. This pre-prepared substrate structure acts as a cushion that absorbs stress and prevents cracking during subsequent deposition and service, eliminating the need for post-deposition repair or replacement.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The invention changes the physical parameters of the substrate surface by controlling the grain size distribution of the crystalline phase. By adjusting the grain size from larger at the bottom to smaller at the top, the substrate achieves optimal mechanical properties that prevent surface indentation and cracking during amorphous layer deposition.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If amorphous metal layer is deposited on crystalline substrate, then adhesion is improved, but manufacturing complexity increases

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges the substrate preparation and coating deposition processes into a unified manufacturing approach. The crystalline gradient structure is created as part of the substrate preparation, and the amorphous layer deposition is performed in a continuous manner, eliminating the need for separate intermediate steps and reducing overall manufacturing complexity despite the sophisticated microstructure achieved.

Inventive Principle:

Principle #5Merging (Combining)

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 multilayer gradient structure exhibits increased yield strength, ultimate tensile strength, wear resistance, and corrosion resistance, with improved adhesion and reduced surface indentation, making it suitable for diverse applications including electronic devices and biocompatible materials.

Implementation Method 1

depositing a metal layer having a first plurality of metal particles arranged in an amorphous structure on a substrate

Methodology Applied

Scientific EffectPhysical Vapour Deposition: Physical Vapour Deposition

Implementation Method 2

the surface indentation and non-substantial cracking are significantly reduced by the high diffusion factor of the crystalline structure

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 3

the substrate is processed by a physical treatment to form the crystalline structure

Methodology Applied

Scientific EffectMechanical deformation: Deformation

Data Source

PatentUS10895006B2Metallic structure

Publication Date: 2021.01.19

AI summary

A metallic structure includes a first plurality of metal particles arranged in an amorphous structure; a second plurality of metal particles arranged in a crystalline structure having at least two grain sizes, wherein the crystalline structure is arranged to receive the amorphous structure deposited thereon; wherein the grain size is arranged in a gradient structure.