Electromagnetic Relay Alloy Layer Diffusion Coating
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Solution Overview
Problem
Existing electromagnetic relays lack high wear resistance, high corrosion resistance, and good magnetic properties due to insufficiently grown metallic structures in chrome-containing alloys and increased magnetic resistance from thick chrome diffusion layers.
Innovation Solution
An electromagnetic relay with a magnetic component featuring an iron component processed to include a diffusion-coated alloy layer of Cr, V, Ti, or Si, with a thickness ranging from 5 to 60 µm, which provides high wear resistance, corrosion resistance, and maintains good magnetic properties by controlling the alloy layer thickness to prevent increased magnetic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Ni plating layers are made thicker to improve corrosion resistance, then corrosion resistance is improved, but component mating is affected
Solution Approach 1:
The invention changes the plating material from nickel to chrome, and controls the plating thickness within a specific range (0.5-5 μm). This parameter change allows achieving adequate corrosion resistance while avoiding the mating problems caused by thick nickel plating layers.
2Reliability
If chrome diffusion layer is made thicker to improve corrosion resistance, then corrosion resistance is improved, but magnetic resistance increases
Solution Approach 1:
The invention controls the chrome diffusion layer thickness within a specific range (0.5-5 μm) and uses a two-stage heat treatment process. This parameter control ensures adequate corrosion resistance while preventing excessive magnetic resistance that would occur with thicker chrome layers.
3Reliability
If alloy elements are added to improve magnetic properties, then magnetic properties are improved, but metallic structure growth becomes insufficient
Solution Approach 1:
The invention uses specific alloy elements (Si: 0.01-3.0 wt%, Mn: 0.01-3.0 wt%, Cr: 0.01-2.0 wt%, Al: 0.01-2.0 wt%, Ti: 0.01-1.0 wt%, V: 0.01-1.0 wt%, Nb: 0.01-1.0 wt%, Ta: 0.01-1.0 wt%, B: 0.001-0.1 wt%, P: 0.001-0.1 wt%) and applies two-stage heat treatment. This combination allows achieving good magnetic properties while ensuring adequate metallic structure growth.
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 achieves high wear resistance, corrosion resistance, and good magnetic properties by ensuring the alloy layer does not hinder the growth of the metallic structure, thus enhancing the relay's performance and longevity.
Implementation Method 1
the alloy layer is formed by diffusion-coating of at least one element selected from the group consisting of Cr, V, Ti, Al, and Si
Implementation Method 2
The contact is open and closed in cooperation with magnetization and demagnetization of the electromagnetic device
Data Source
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AI summary
An electromagnetic relay (100) has high wear resistance, high corrosion resistance, and good magnetic properties. The electromagnetic relay (100) includes a magnetic component including an alloy layer on its surface formed by diffusion-coating of at least one element selected from the group consisting of Cr, V, Ti, and Al. The alloy layer has a thickness of 5 to 60 µm, inclusive.