Plow Blade Edge Carbide Insert Brazing
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Solution Overview
Problem
Snow plow and grader blades face durability and performance issues due to wear from rough terrain and cold weather, with existing solutions being costly and difficult to maintain, particularly the brittle cast iron wear blocks which are prone to breakage and require frequent replacement.
Innovation Solution
A plow blade edge system featuring carbide inserts brazed into steel sections, with wear blocks integrated into the blade edge to enhance durability and reduce maintenance, using a method that forms channels in the blade edge and applies multiple layers of braze and carbide inserts for secure bonding, thereby creating a robust and abrasion-resistant surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metallic plow edges are used, then the blade can perform basic cutting function, but the edges are excessively damaged or destroyed due to wear and corrosion requiring frequent repair or replacement
Solution Approach 1:
The patent applies composite materials by combining a metallic blade body with carbide inserts brazed into recesses in the blade edge. The carbide inserts provide superior wear and corrosion resistance compared to conventional metallic edges alone, creating a composite structure that leverages the strengths of both materials to extend service life and improve reliability in harsh snow plowing conditions.
Solution Approach 2:
The patent applies local quality by placing carbide inserts only in the specific regions where wear and corrosion occur most severely (the cutting edge and high-stress contact areas), rather than making the entire blade from expensive carbide material. This localized application of enhanced material properties optimizes durability while controlling costs.
2Force
If cast iron wear blocks are used to support load on the blade, then part of the load is supported, but the blocks are brittle and prone to fracturing or breakage under impacts requiring expensive maintenance and replacement
Solution Approach 1:
The patent replaces brittle cast iron wear blocks with a composite structure consisting of a metallic block body with carbide inserts brazed into recesses. This composite construction maintains the load support capability of the block while the carbide inserts provide superior toughness and impact resistance, eliminating the fracturing problem associated with conventional cast iron blocks.
Solution Approach 2:
The patent changes the material parameters of the wear block by transitioning from homogeneous cast iron to a composite structure with carbide inserts. This parameter change fundamentally alters the mechanical properties, providing both the required load support and the impact resistance that brittle cast iron lacks.
3Strength
If carbide inserts are brazed into blade edges using conventional methods, then the inserts can be secured, but the process requires precise temperature control and complete melting of braze material which increases manufacturing complexity
Solution Approach 1:
The patent applies preliminary action by providing recesses in the blade edge that are pre-configured to receive the carbide inserts. The recesses include features such as tapered walls and drainage holes that facilitate proper insert placement and braze material flow before the actual brazing operation occurs. This preliminary preparation simplifies the brazing process and ensures consistent bonding strength.
Solution Approach 2:
The patent uses braze material as an intermediary substance that bonds the carbide inserts to the metallic blade body. The braze material fills the interface between the insert and blade, creating a strong metallurgical bond while accommodating slight misalignments and providing a transition between the dissimilar materials.
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 significantly extends the life of both the blade edges and wear blocks, reduces maintenance costs, and enhances the durability of the plow blade, while providing improved protection against abrasive wear and impact.
Implementation Method 1
heating the first layer and the at least second layer of braze, and the first carbide insert and the at least second carbide insert at a temperature of at least 1500 degrees Fahrenheit
Implementation Method 2
melting the first layer and the at least second layer of braze completely around the first carbide insert and around a majority of the at least second carbide insert for securing the first carbide insert and the at least second carbide insert within the channel
Implementation Method 3
reducing the undesirable abrasive action on the blade edge
Data Source
AI summary
The present disclosure provides a plow blade edge device for mounting to a moldboard of a plow comprising at least one adapter blade including a bottom edge having selectively carbide insert(s) along at least a portion of the bottom edge. The disclosure further provides for a method of brazing the carbide insert(s) in a cavity along at least a portion of the bottom edge. The device further includes at least one wear block selectively reversible to present the adapter blade at a first angle or a second angle. The at least one wear block can include a bottom edge having a carbide insert along at least a portion of the bottom edge.