Hot-Forming Tool Oxide Layer Segmentation
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Solution Overview
Problem
Existing methods for producing hot-forming tools, such as piercing mandrels and rolling rods, fail to effectively address thermal and mechanical loads, leading to rapid tool failure and product quality issues due to limited oxide layer thickness and mechanical wear, necessitating expensive materials like molybdenum or ceramic coatings with restricted depth and coverage.
Innovation Solution
A method involving a metallic base body equipped with spaced metallic disk rings, where the gaps between the disks are oxidized and sealed using thermochemical processes, allowing for enhanced thermal insulation and wear resistance without altering the base body's dimensions, and optionally filled with thermal plasma spraying to create an alternating surface with full and empty areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thick oxide layer is produced on the tool surface, then thermal insulation is improved, but the oxide layer peels off quickly or is reduced by mechanical wear leading to tool failure
Solution Approach 1:
The tool surface is segmented into alternating elevations and recesses, creating a profiled structure. This segmentation allows the oxide layer to form on the elevations while the recesses provide mechanical interlocking and stress relief, preventing peeling and improving both thermal insulation and reliability
Solution Approach 2:
The tool surface is pre-profiled with elevations and recesses before oxide layer formation. This preliminary action creates a structured substrate that enhances oxide layer adhesion and prevents peeling during subsequent use, allowing thick insulating layers to maintain their integrity
2Temperature
If material removal depth is increased to create thicker insulating layers, then thermal insulation is improved, but the mechanical strength and integrity of the tool are compromised
Solution Approach 1:
Instead of removing material in the radial direction only, the invention creates a three-dimensional profile with elevations and recesses. This dimensional approach allows thick oxide layers to form on the elevations while the base body retains its full radial strength, decoupling insulation thickness from structural integrity
3Reliability
If expensive materials like molybdenum are used, then thermal insulation and wear resistance are improved, but production costs increase significantly
Solution Approach 1:
The invention creates a composite structure with a carbon steel base body and a thick oxide layer on the profiled surface. This composite approach combines the cost-effectiveness of carbon steel with the protective properties of the oxide layer, achieving high service life without using expensive molybdenum materials
Solution Approach 2:
The invention changes the chemical composition of the surface layer by forming a thick oxide layer through controlled oxidation. This parameter change transforms the surface properties to provide wear resistance and thermal insulation, replacing the need for expensive alloying elements
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 significantly extends the service life of hot-forming tools, reduces production costs, minimizes rejects, and lowers energy consumption by maximizing thermal insulation and minimizing mechanical wear, enabling the production of difficult-to-roll products with increased quantities and reduced production times.
Implementation Method 1
the surfaces of the disk rings or disks and / or preferably additional materials (for example ceramic particles, cast iron particles or wires) provided and introduced into the gaps are brought to oxidation by means of a thermochemical process, the gaps being caused by the Formation of the metallic oxides or scale can be narrowed or completely sealed
Implementation Method 2
the gaps or the narrowed gaps are closed, for example, by means of thermal plasma spraying
Data Source
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AI summary
The present invention relates to a method for producing a hot forming tool (1) comprising at least one metallic main body (5), which is characterized in that at least portions of the main body (5) are fitted with metallic flat rings or discs (7) arranged at a distance from the main body (5) in such a way that, when the metallic flat rings or discs (7) are applied, gaps (8) are created between the flat rings or discs (7), the surfaces of the flat rings or discs (7) being oxidized by means of a thermochemical process and the gaps being narrowed or completely closed by the formation of the metallic oxides or scale.