T-die Lip Cladding for Resin Film Wear Resistance
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Solution Overview
Problem
Existing T-dies for manufacturing resin films face challenges in achieving high-quality, durable lip portions with sharp edges and low material costs, as previous methods suffer from defects like peeling, cracking, and high production costs due to complex and expensive manufacturing processes.
Innovation Solution
A T-die with a lip portion formed by laser build-up welding using a corrosion-resistant and wear-resistant alloy powder, where a cladding layer with metal borides or carbides is dispersed in a binder phase, and a hard chromium plating layer is applied to the inner wall surface for reduced friction and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a WC-based coating layer is provided to the lip portion by flame spraying, then the lip portion has high hardness and wear resistance, but the coating layer is brittle and suffers from peeling, cracking, or chipping upon grinding and polishing
Solution Approach 1:
The patent changes the manufacturing method parameter from flame spraying to laser cladding. This parameter change transforms the coating process to produce a coating layer with a metallurgical bond to the base material, eliminating the brittle structure caused by flame spraying while maintaining high hardness and wear resistance through controlled laser parameters and alloy composition
Solution Approach 2:
The patent uses a composite material structure consisting of a nickel-based or cobalt-based alloy containing hard particles (WC, TiC, TaC, NbC) dispersed in a metallic binder. This composite structure provides both the hardness from the ceramic particles and the toughness from the metallic binder, preventing brittleness while maintaining wear resistance
2Manufacturing precision
If a super hard alloy lip member is bonded to the die main body by ceramic type adhesive, then the lip edge can be finished into a sharp edge, but the super hard alloy has inferior adhesion with hard chromium plating layer and requires large adhesion area
Solution Approach 1:
The patent changes the material parameter of the lip portion from super hard alloy to nickel-based or cobalt-based alloy with hard particles. This parameter change enables excellent adhesion to hard chromium plating layer while maintaining the ability to form sharp edges through laser cladding and subsequent grinding, eliminating the adhesion problems associated with super hard alloys and ceramic adhesives
Solution Approach 2:
The patent applies local quality by providing the cladding layer containing hard particles specifically at the lip portion where wear resistance and sharpness are critical, while the rest of the die can have different surface treatments. This localized approach maintains adhesion strength without requiring large adhesion areas
3Reliability
If Hot Isostatic Process (HIP) is used to bond corrosion resistant and wear resistant alloy powder to die main body, then the lip portion has dense metallographic structure with less defects, but extremely complicated, expensive, and large-scaled manufacturing equipment is required
Solution Approach 1:
The patent extracts the essential function of HIP (producing dense, defect-free metallographic structure) and achieves it through a simpler laser cladding process. The laser cladding method directly melts and solidifies the alloy powder on the die surface, creating a dense structure without requiring the complex high-pressure gas environment of HIP equipment
Solution Approach 2:
The patent replaces the mechanical/physical system of HIP (high pressure, high temperature gas environment) with a thermal system (laser beam heating). This substitution achieves similar densification results through localized melting and solidification, eliminating the need for expensive and complex HIP equipment
4Manufacturing precision
If HIP process is used to bond alloy powder to die main body, then the lip portion has sharp edge at high accuracy, but the die main body is distorted and bent due to exposure to high temperature and high pressure
Solution Approach 1:
The patent applies local quality by using laser cladding to treat only the lip portion locally rather than heating the entire die main body as in HIP. This localized heating approach achieves the desired dense structure and sharp edge accuracy at the lip while minimizing thermal effects on the rest of the die, preventing distortion and bending
Solution Approach 2:
The patent extracts the essential function of achieving sharp, accurate edges from the HIP process and achieves it through laser cladding followed by precision grinding. This approach obtains the same edge quality without the global thermal and pressure effects that cause die main body distortion
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 T-die with improved durability, reduced material costs, and the ability to maintain sharp edges without defects, while minimizing heat effects on the base material and avoiding complications like peeling and cracking, thus enhancing the manufacturing efficiency and quality of resin films.
Implementation Method 1
a cladding layer formed by laser build-up welding to a base material with a powder of a corrosion resistant and wear resistant alloy
Implementation Method 2
the cladding layer has a metallographic structure in which metal borides or metal carbides are dispersed in a binder phase
Implementation Method 3
a hard chromium plating layer is applied to the inner wall surface for reduced friction and corrosion resistance
Implementation Method 4
a powder of a corrosion resistant and wear resistant alloy
Data Source
AI summary
On at least the edge portion (9e) of the lip portion (9) of a T-die (1), a cladding layer (10) is provided. The cladding layer is formed by laser build-up welding to a base material with a powder of a corrosion resistant and wear resistant alloy comprising a nickel-based alloy or a cobalt-based alloy. The cladding layer has a metallographic structure in which metal borides are dispersed in a binder phase. The lip portion has high quality and has high durability. The manufacturing costs of the T-die can also be kept relatively low.