Knife Blade Edge Hardfacing Using Arc-Welded Hard Material

Solution Overview

Problem

The existing method of manufacturing knife blades using laser deposition is inefficient due to the challenges of accurately and efficiently depositing the harder material powder onto the blade preform, often resulting in excess material and a slow process.

Innovation Solution

The use of arc welding to deposit a harder material as a rod or wire onto the blade preform, allowing for precise control over the amount and location of the material, with the option of using a metal cored rod for enhanced properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If laser deposition is used to deposit the second material onto the blade preform, then a hard knife edge can be obtained, but the process is slow and requires special attention to ensure correct powder amounts

Engineering Contradiction:

Improveprecision of material depositionVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the laser-based deposition system with a mechanical wire feeding system. The wire is fed through a guide tube into the welding area where an electric arc melts and deposits the material. This mechanical substitution eliminates the complexity of laser-powder interaction control while maintaining precise material placement through controlled wire feeding rates and arc positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental deposition parameters by switching from powder-form material delivered by laser to wire-form material delivered by mechanical feeding. This parameter change simplifies the deposition process while improving both precision and speed, as wire feeding is more controllable and faster than powder deposition.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If laser deposition is used to deposit the second material onto the blade preform, then a hard knife edge can be obtained, but excess material may be used and required properties may not be achieved

Engineering Contradiction:

Improveaccuracy of material placementVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent replaces the laser-based deposition system with a mechanical wire feeding system. The wire is fed through a guide tube into the welding area where an electric arc melts and deposits the material. This mechanical substitution eliminates the complexity of laser-powder interaction control while maintaining precise material placement through controlled wire feeding rates and arc positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The arc welding process inherently controls material deposition through the self-regulating nature of the electric arc. The arc automatically adjusts to consume only the amount of wire needed for the weld, eliminating the risk of excess powder deposition that occurs with laser methods where powder can accumulate if not perfectly synchronized with the laser beam.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If powder is used for laser deposition, then the second material can be deposited onto the blade preform, but special attention is required to ensure correct amounts at desired locations

Engineering Contradiction:

Improvesimplicity of material depositionVSAvoidcomplexity of deposition control

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces the laser-based deposition system with a mechanical wire feeding system. The wire is fed through a guide tube into the welding area where an electric arc melts and deposits the material. This mechanical substitution eliminates the complexity of laser-powder interaction control while maintaining precise material placement through controlled wire feeding rates and arc positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method enables the precise deposition of a harder material onto the knife blade edge, improving durability and efficiency in the manufacturing process, resulting in a sharper and more effective cutting edge.

Implementation Method 1

The arc welding tool creates an electric arc to the blade preform or to the rod which melts and deposits the second material on the edge of the blade preform

Methodology Applied

Scientific EffectElectric arc: Electric Arc

Data Source

PatentUS20230166412A1Method of manufacturing a knife blade and knife blade

Publication Date: 2023.06.01 FISKARS FINLAND OY AB

AI summary

A method of manufacturing a knife blade includes preparing a blade preform of a first material, depositing a second material which is harder than the first material on an edge of the blade preform by arc welding, and sharpening the deposited second material to prepare a knife blade with a sharp edge. A knife blade is also provided and includes a blade section of a first material, and an edge of the blade section is provided with an arc welded layer of a second material which is shaped as a sharp edge, where the second material is harder than the first material.