Multimaterial Component Joining With Local Wear-Resistant Inserts
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Solution Overview
Problem
Existing methods for manufacturing multimaterial components fail to achieve optimal functionality and cost-efficiency due to the need for exact form and measure tolerances, complex manufacturing processes, and the incompatibility of different materials, leading to increased costs and potential damage during assembly.
Innovation Solution
A method for manufacturing multimaterial components by connecting pieces with loose dimensional and form requirements, using a basic material body with pre-formed joining points and wear-resistant pieces made of specific alloys, joined with an additional material to form a joint without molten pools, allowing for separate manufacturing of materials with optimal mechanical and tribological characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If exact form and measure tolerances are required for joining pieces of different materials, then the assembly precision is improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The component is divided into a body part and separate wear protection pieces that are manufactured independently with loose tolerances, then joined together. This segmentation allows each part to be optimized separately without requiring tight tolerances on the final assembly.
Solution Approach 2:
The joining method is changed from mechanical fitting requiring exact tolerances to a thermal joining process (such as diffusion bonding or metallurgical bonding) that can accommodate loose dimensional and form requirements while still achieving strong, reliable joints.
2Reliability
If wear resistant materials are used throughout the entire construction, then the wear resistance is improved, but the cost and ecological efficiency worsen due to excessive material usage
Solution Approach 1:
Wear protection pieces made of wear-resistant materials are applied only to specific areas of the body part where wear occurs, rather than manufacturing the entire construction from wear-resistant material. This local application reduces material consumption and cost while maintaining necessary wear resistance at critical locations.
3Adaptability or versatility
If different materials are joined together to create multimaterial constructions, then the functionality and performance are improved, but the manufacturing precision and assembly difficulty worsen due to different material behaviors
Solution Approach 1:
The body part is prepared in advance with joining points (such as recesses, surfaces, or geometric features) that are designed to receive the wear protection pieces. This preliminary preparation ensures proper alignment and fit during assembly, compensating for the different material behaviors and loose tolerances of the separately manufactured pieces.
4Ease of manufacture
If traditional joining methods are used for multimaterial constructions, then the assembly is simplified, but the manufacturing cost and process complexity increase due to the need for exact tolerances
Solution Approach 1:
The joining process parameters are changed from mechanical assembly requiring exact tolerances to thermal or metallurgical joining processes (such as diffusion bonding, brazing, or direct metal deposition) that can join pieces with loose dimensional and form requirements while creating strong, integral joints.
Data Source
Figure 1A~3B
Figure 4~6
AI summary
A method for manufacturing a multimaterial component or construction, whereby a body (1, 7) is formed in said method of a basic material and at least one piece (3, 4, 5, 9) formed of a wear resistant material being joined to said body at a temperature of not more than 80 % of the lowest melting temperature of the materials to be joined. The invention also comprises the use of a multimaterial component or construction manufactured by means of said method.