Nickel-Alloy Seal Ring Casting for Low Leakage and Wear
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Solution Overview
Problem
Existing seal rings for machines, particularly those used in construction and mining equipment, face issues with suboptimal operations due to surface roughness and improper grain microstructure, leading to leakage and excessive wear. Additionally, traditional alloy compositions are not compatible with low-cost centrifugal casting methods, requiring costly post-casting processing.
Innovation Solution
A seal ring made from a nickel-based alloy with specific composition ranges: less than 4% silicon (Si), greater than 13.5% chromium (Cr), less than 3% boron (B), less than 2% carbon (C), and greater than 70% nickel (Ni), which is centrifugally cast and then machined to predetermined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional alloy compositions are used for seal rings, then the seal rings can be manufactured using sand casting, but the manufacturing cost increases and the seal performance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the alloy by reducing silicon content to less than 4% and carbon content to less than 2%, while increasing chromium content to greater than 13.5%. This parameter change enables the alloy to be suitable for centrifugal casting while achieving improved seal performance and reduced leakage.
Solution Approach 2:
The patent replaces the sand casting manufacturing method with centrifugal casting. This substitution eliminates the need for costly post-casting processing while producing seal rings with improved grain microstructure and surface roughness, thereby resolving the contradiction between manufacturing cost and seal performance.
2Reliability
If seal rings are manufactured with improper grain microstructure, then the manufacturing process is simplified, but the seal rings suffer from excessive wear and leakage
Solution Approach 1:
The patent uses specific alloy composition parameters (low silicon less than 4%, low carbon less than 2%, high chromium greater than 13.5%) to control the grain microstructure formation during centrifugal casting. This parameter control achieves the desired crystal structure and surface roughness without requiring complex post-processing, thereby improving durability while managing structural complexity.
3Ease of manufacture
If centrifugal casting is used for seal rings, then the manufacturing cost is reduced, but traditional alloys produce suboptimal grain microstructure and surface roughness
Solution Approach 1:
The patent modifies the alloy composition parameters specifically to be compatible with centrifugal casting. By reducing silicon to less than 4% and carbon to less than 2%, while increasing chromium to greater than 13.5%, the alloy produces optimal grain microstructure and surface roughness during centrifugal casting, achieving both cost reduction and manufacturing precision.
Solution Approach 2:
The patent creates a composite alloy system combining nickel (greater than 70%), chromium (greater than 13.5%), and controlled amounts of other elements. This composite material formulation is specifically designed to work with centrifugal casting, producing the desired microstructure and surface properties that single-element materials cannot achieve alone.
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 nickel-based alloy allows for the production of seal rings with improved crystal structure and morphology, resulting in reduced leakage and increased durability, while also enabling cost-effective centrifugal casting without the need for costly post-processing.
Implementation Method 1
a method of making a seal ring includes producing a rough seal ring from an alloy using centrifugal casting
Data Source
AI summary
A nickel-based alloy for forming a seal ring is disclosed. Such seal rings, in use may be static or rotating and may be used in a variety of applications, such as in wheel assemblies of machines. Using the alloy, the seal ring may be manufactured using a centrifugal casting method. The disclosed alloy includes a chromium content greater than at least 13.5% by weight, a boron content less than 3% by weight, a carbon content less than 2% by weight, and nickel content greater than 70% by weight. The nickel alloy may have a carbon plus boron atomic content divided by chromium atomic content less than 1.1. This alloy allows for the rapid cooling of centrifugal casting while maintaining a grain morphology suitable for relatively low leakage and relatively high durability. When the alloy is formulated, the seal ring is formed by centrifugal casting.