Laser Brazing Annular Seal on Track Link
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Solution Overview
Problem
Existing undercarriage track joint assemblies face high maintenance costs due to wear and complexity, particularly from seals between links, which reduce wear life and increase complexity.
Innovation Solution
Laser brazing an annular metal sealing washer to track links to form a seal assembly with annular fillets between the washer and link surfaces, providing a durable and cost-effective sealing solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If seals are positioned between inserts and bushings as in the '947 publication, then sealing function is provided, but device complexity and cost increase while wear life decreases
Solution Approach 1:
The sealing function is extracted from the complex multi-component seal assembly and implemented through a simplified method: laser brazing annular sealing washers directly to the bushings. This removes the need for separate seal elements positioned between inserts and bushings, thereby reducing device complexity while maintaining the sealing function through the brazed washer configuration
Solution Approach 2:
The mechanical seal system relying on friction and contact between multiple components is replaced with a thermal bonding process (laser brazing). The brazed joint creates a permanent, low-friction sealing interface that eliminates the need for sliding seal elements, thereby reducing complexity and improving wear life
2Reliability
If seals are positioned between inserts and bushings, then sealing is achieved, but wear life of the track joint assembly decreases
Solution Approach 1:
The mechanical sliding seal interface is replaced with a thermally bonded brazed joint. The laser brazing process creates a metallurgical bond between the sealing washer and the bushing, eliminating relative motion and friction at the sealing interface. This substitution dramatically improves wear life while maintaining the sealing function through the configured brazed assembly
3Reliability
If conventional brazing or welding is used to attach sealing washers, then sealing is provided, but heat damage and distortion occur
Solution Approach 1:
Conventional thermal brazing or welding processes are replaced with laser brazing technology. The laser provides highly localized and controlled heat input that precisely melts the filler metal at the joint interface without excessively heating the base materials. This substitution maintains the sealing function through reliable brazed joints while preserving dimensional stability and preventing heat-induced distortion
Solution Approach 2:
The thermal parameters of the brazing process are changed by using laser heating instead of conventional thermal sources. The laser enables precise control of temperature distribution, heating rate, and heat input duration. These parameter changes allow the brazing process to achieve reliable joints while minimizing the heat-affected zone and preventing distortion of the sealing washer and bushing components
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 enhances the wear life and durability of track joint assemblies, reducing maintenance costs and complexity while maintaining the effectiveness of the seal, even with wear-resistant coatings.
Implementation Method 1
performing the laser brazing to form at least one of an annular fillet of braze material between the first track link and at least a portion of an inner diameter surface of the washer and an annular fillet of braze material between the first track link and at least a portion of an outer diameter surface of the washer
Implementation Method 2
laser brazing an annular, metal sealing washer to a first track link
Data Source
AI summary
A method of manufacturing an undercarriage track joint assembly includes forming at least a first portion of a seal assembly by laser brazing an annular, metal sealing washer to a first track link of the undercarriage track joint assembly. The method may also include performing the laser brazing to form at least one of an annular fillet of braze material between the first track link and at least a portion of an inner diameter surface of the washer and an annular fillet of braze material between the first track link and at least a portion of an outer diameter surface of the washer. The method may still further include inserting a second portion of the seal assembly into a counterbore formed in an axial face of a second track link of the track joint assembly such that an axial sealing face of the washer opposite from the first track link slidably engages with the second portion of the seal assembly on the second track link of the track joint assembly to form a sealing surface between the first and second track links.