Laser-Clad Plain Bearing Ring for High-Load Slidability
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Solution Overview
Problem
Plain bearings made of monolithic bronze rings often experience plastic deformation under high loads in applications like hydraulic steel construction, leading to reduced bearing operating time and potential failures due to insufficient load-bearing capacity and corrosion resistance.
Innovation Solution
A plain bearing ring with a metallic base material having a higher elastic limit than the laser-clad layer, where the laser-clad layer is applied using Directed Energy Deposition (DED) to create a strong, friction-reducing and corrosion-protective connection, enhancing load-bearing capacity and slidability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a monolithic bronze ring is used to ensure good slidability, then the sliding properties are improved, but the load-bearing capacity is insufficient and plastic deformation occurs under high loads
Solution Approach 1:
The patent applies a composite material structure consisting of a bronze sliding layer deposited on a steel base material. The bronze layer provides excellent slidability and low friction, while the steel substrate provides high strength and load-bearing capacity. This composite structure resolves the contradiction by combining materials with complementary properties, allowing the bearing to simultaneously achieve good sliding characteristics and high load resistance without plastic deformation.
2Ease of operation
If a monolithic bronze ring is used to ensure good slidability, then the sliding properties are improved, but corrosion resistance is insufficient
Solution Approach 1:
The composite structure of bronze sliding layer on steel base material addresses the corrosion resistance issue. The steel substrate provides superior corrosion resistance compared to bronze, while the bronze layer maintains good sliding properties. This layered composite material solution allows the bearing to simultaneously achieve both good slidability and enhanced corrosion resistance, improving overall reliability in corrosive environments.
3Strength
If the elastic limit of the bearing material is exceeded to increase load rating, then the load-bearing capacity is improved, but plastic deformation occurs leading to reduced operating time
Solution Approach 1:
The composite material structure with steel base and bronze layer allows the bearing to withstand loads above the elastic limit of bronze without plastic deformation, as the steel substrate provides the necessary strength. This enables extended bearing operating time and increased load rating simultaneously, as the high-strength steel prevents permanent deformation while the bronze layer maintains sliding functionality.
Solution Approach 2:
The invention changes the material parameter (elastic limit) by using steel instead of bronze for the base material. Steel has a significantly higher elastic limit and yield strength compared to bronze, allowing the bearing to operate at higher loads without exceeding the elastic limit and undergoing plastic deformation. This parameter change enables both increased load rating and extended operating time.
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 solution provides a plain bearing ring with increased load rating and reduced plastic deformation, while maintaining good slidability and corrosion protection, enabling safer and more reliable operation under high loads.
Implementation Method 1
the base material is heated by a laser and melted. At the heated point, the powder or wire material melts and bonds with the base material
Implementation Method 2
an inert gas mixed with fine powder or wire material, the material of the layer to be applied, is supplied (Directed Energy Deposition (DED) method)
Implementation Method 3
the applied layer is a laser-clad layer. Such a laser-clad layer represents a reliable, inter-metallic connection between the applied layer and the base material
Data Source
AI summary
A plain bearing ring is formed from a metallic base material and a laser-clad sliding layer on the base material, the base material having a higher elastic limit than a material of the sliding layer. Also a plain bearing including at least one such plain bearing ring and a method of forming the plain bearing ring.