Wear-Resistant Element Casting via Temporary Aggregation Structure
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Solution Overview
Problem
Existing methods for producing wear-resistant elements, such as tools for crushing or abrasion, fail to achieve optimal mechanical characteristics like toughness, hardness, and temperature resistance, while also being cost-inefficient and limited in precision due to high production costs and sintering requirements.
Innovation Solution
A method involving a temporary aggregation structure with open pores that is heated to evaporate, allowing a metal powder mixture to consolidate and be cast with a molten metal, creating a core with precise conformation and reduced production costs, using either polymeric or metal materials for the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sintering process is used to preform the ceramic insert with desired conformation, then the insert maintains its shape and structure, but the production costs increase and molding precision is limited
Solution Approach 1:
The patent applies preliminary action by pre-assembling the ceramic insert components with desired conformation before the casting process, using a temporary support structure that guides the molten metal flow and ensures precise final conformation without requiring expensive sintering of the entire insert
Solution Approach 2:
The patent uses a disposable temporary support structure made of inexpensive materials that is eliminated after serving its purpose during casting, replacing the need for expensive sintering processes while achieving the desired insert conformation
2Ease of manufacture
If the ceramic insert is preformed with excessive or reduced conformation, then the production costs increase, but the mechanical quality of the final element is reduced
Solution Approach 1:
The patent applies parameter changes by controlling the conformation parameters of the temporary support structure and ceramic insert assembly to achieve optimal final dimensions, ensuring both cost-effectiveness and high mechanical quality through precise parameter control rather than excessive material usage
3Device complexity
If traditional casting methods are used on ceramic inserts, then the production process is simple, but the elements cannot achieve high toughness, hardness, and temperature resistance
Solution Approach 1:
The patent applies composite materials by combining ceramic materials with high strength-to-weight ratio and heat resistance with metal matrix materials, creating a composite structure that achieves superior toughness, hardness, and temperature resistance while maintaining production simplicity through the casting process
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 method produces elements with enhanced toughness, hardness, and cost-effectiveness by allowing precise conformation and reduced production costs, overcoming limitations of existing methods in mechanical quality and production expenses.
Implementation Method 1
a temporary aggregation structure is prepared with at least partially open pores and which has the characteristic that it is volatilized or in any case at least partly eliminated when it is subjected to heating
Implementation Method 2
the molten metal material can penetrate into the apertures and into the interstices of the insert itself
Data Source
AI summary
The method for the production of an element subject to wear, comprising a metal matrix and at least a core of hard material. The method provides a first step in which a temporary aggregation structure is prepared with at least partly open pores, which volatilize or in any case eliminate at least partly when subjected to heating. A second step in which, on the whole internal and external surface of said temporary aggregation structure, a liquid mixture of a binder with metal powders which contain hard elements or their precursors is uniformly distributed. A third step in which the temporary aggregation structure is deteriorated by means of a thermal action of controlled heating, so as to take at least part of the temporary aggregation structure to evaporation, rendering free a volume inside the core, and to consolidate the mixture according to the conformation of the temporary aggregation structure. A fourth step in which the core is disposed in a mold so as to only partly occupy the free volume of the mold. A fifth step in which a molten metal material is cast in the mold, which metal occupies the free volume and the volume that has been made free, both inside and outside the core, so as to anchor to the latter and thus form a single body.