Patent Application
20160001358
The present disclosure is directed to methods and a system for forming a layer of cladding material on a component.
Cladding is a metalworking technique for bonding metals together. For example, a cladding process can be used to bond a hard metal coating onto a comparatively less hard metal substrate.
Laser cladding is a technique in which a laser is used as part of a process of depositing a layer of cladding material onto an underlying metal substrate. The laser heats and melts cladding feedstock material, the substrate, or both, and the cladding feedstock material is deposited onto the substrate. The cladding feedstock material cools and hardens into a layer of cladding material on the substrate, resulting in a metallurgical bond between the cladding material and the substrate. Often, however, further processing of the substrate, the cladding material, or both is performed. For example, the shape of the substrate, the cladding material, or both, may be modified in order to achieve a desired shape.
U.S. Patent Application Publication No. 2013/0248219 (“the '219 publication”) purports to describe a laser cladding surface treatment procedure for applying a cladding material to surfaces of a metal enclosure. In particular, the '219 publication describes a laser cladding process to inlay a cladding material into a groove of a metal enclosure. The groove at least partially constrains the shape of the cladding material. Following the laser cladding process, excess cladding material extends out of the groove, and a finishing process is performed to remove this excess cladding material such that the cladding material is substantially flush with the adjacent surface of the metal enclosure.
While the laser cladding surface treatment procedure of the '219 publication may be suitable for some applications, it may still be less than optimal. In particular, some applications may require a layer of cladding material to be formed across a surface that is not characterized by a groove. Moreover, surface tension effects that arise when melted cladding feedstock material is deposited onto a surface and cools can influence the shape of the resulting layer of cladding material on the surface.
The present disclosure is directed at solving one or more of the problems set forth above and/or other problems in the art.
In an embodiment, a method is provided for processing a component. The method includes performing a metal deposition process to deposit a layer of cladding material onto a surface of the component and onto a support surface of a mold member. The mold member is different from the component. The method further includes forming a metallurgical bond between the cladding material and the component.
In another embodiment, a method is provided for forming a layer of cladding material on a surface of a component. The surface extends from a first edge to a second edge. The method includes positioning a first mold member generally adjacent to the first edge of the component. The first mold member includes a first support surface. The method further includes positioning a second mold member generally adjacent to the second edge of the component. The second mold member includes a second support surface. The method further includes performing a metal deposition process to deposit a layer of cladding material onto the surface of the component between the first and second edges and onto the first and second support surfaces of the first and second mold members. The layer of cladding material extends laterally beyond the first and second edges where the cladding material is deposited onto the first and second support surfaces. The method further includes forming a metallurgical bond between the cladding material and the component, and removing cladding material that extends laterally beyond the first and second edges.
In yet another embodiment, a system is provided for forming a layer of cladding material on a component. The system includes a mold member configured for cooperating with the component during a metal deposition process. The system further includes a fixture configured for holding the component during the metal deposition process. The system further includes a metal deposition system configured for performing the metal deposition process to deposit cladding material onto the mold member and the component. The mold member is formed of materials for preventing a metallurgical bond from forming between the cladding material and the mold member.
This disclosure describes aspects of a method of processing a component, a method of forming a layer of cladding material on a surface of a component, and a system for forming a layer of cladding material on a component. According to various aspects of the methods, a layer of cladding material is deposited onto a surface of a component and onto a support surface of a mold member that is positioned generally adjacent to the component when the cladding material is deposited. A metallurgical bond is formed between the cladding material and the component, but not between the cladding material and the mold member. The mold member can be removed, leaving the layer of cladding material on the component. The layer of cladding material can be processed to modify its shape. For example, portions of the layer of cladding material can be removed, such as portions that had been above the mold member, or portions above the surface of the component. The system generally includes a mold member, a fixture for holding a component and the mold member, and a metal deposition system. The mold member includes a material selected for preventing a metallurgical bond from forming between the mold member and cladding material deposited by the metal deposition system.
The methods and system described in this disclosure are generally applicable to a wide range of components that receive a layer of cladding material. In order to illustrate the principles of this disclosure, the figures depict and the following text describes an exemplary component in the form of a metal face seal. The metal face seal receives a layer of cladding material, and is of the type used to retain lubricant and exclude contaminants, such as in backhoe, excavator, shovel, truck, and other applications. In a typical seal arrangement in such applications, two metal face seals are arranged with a seal surface of each being in contacting relationship. It will be appreciated, however, that the principles of this disclosure are broadly applicable to other types and shapes of components, as well. Components that receive a layer of cladding material are typically metallic components, or at least include a metallic portion that receives the cladding material. Suitable components under this disclosure can have any form, construction, or composition that is appropriate for receiving a layer of cladding material.
The methods and system described in this disclosure are also generally applicable to a wide range of cladding materials. For example, a cladding material may be added to a component to give the component a desired property, such as a desired structural property and/or a desired aesthetic property. Selection of a cladding material will usually depend upon a particular application. For example, the cladding material may include a metal, or a ceramic/metal composition. Suitable cladding materials will be readily identifiable by interested practitioners. In addition, more than one type of cladding material can be added to a component.
Referring to the figures and beginning with
The system 10 also includes a mold member 30 that is configured for cooperating with the metal face seal 12 during a metal deposition process, as will be described further below. Generally, the metal deposition system deposits cladding material onto both the metal face seal 12 and the mold member 30. A metallurgical bond is formed between the cladding material and the metal face seal 12, but not between the cladding material and the mold member 30. The mold member 30 may be removed after the metal deposition process, or after a metallurgical bond is formed between the cladding material and the metal face seal 12. In the embodiment shown, the mold member 30 includes a first mold member portion 32 and a second mold member portion 34, each of which may also be considered a mold member. The mold member 30 is different from, and forms no part of, the metal face seal 12.
The system 10 also includes a fixture 36 that is configured for holding the metal face seal 12 (and optionally the mold member 30) during a metal deposition process. For example, the fixture 36 can include a three-way chuck 38 configured to securely hold the metal face seal 12. The fixture 36 can also include or be associated with a drive mechanism (not shown) that can be selectively activated to move the metal face seal 12. For example, the fixture 36 can rotate the metal face seal 12, such as to move portions of the metal face seal 12 into the path of the laser beam 18 as part of a metal deposition process. The fixture 36 may also include additional structure (not shown) for holding the mold member 30 during the metal deposition process. It will be appreciated that the fixture 36 may passively hold the metal face seal 12 or mold member 30 without any moving parts.
The metal deposition process can be automated and can be controlled to precisely deposit a layer of cladding material onto a selective surface region of a component. The thickness of the layer of cladding material can be selected depending on a particular application. Depositing a layer of cladding material can involve making one or more passes with the metal deposition system in order to build up an appropriate thickness of cladding material on the metal face seal 12. Similarly, a layer of cladding material can include the build-up of cladding material from one or more passes with the metal deposition system. Depositing a layer of cladding material can involve using one or more types of cladding material, and a layer of cladding material can include one or more types of cladding material.
Referring next to
The metal face seal 12 includes a radially inner sidewall 48 and a radially outer sidewall 50. The sidewalls 48, 50 extend between the sealing surface 44 and the end surface 46. The sidewalls 48, 50 and surfaces 44, 46 define, at least in part, the cross-sectional shape of the metal face seal 12. As shown, the inner sidewall 48 may follow a generally straight-line path between the sealing surface 44 and the end surface 46, whereas the outer sidewall 50 may have varying features between the sealing surface 44 and the end surface 46. Specific details of the sidewalls 48, 50 are not necessary to an understanding of the present disclosure, so such specific details are not provided.
The sealing surface 44 extends in a radial direction R between a radially inner edge 52 and a radially outer edge 54. The inner edge 52 may be located at the intersection of the sealing surface 44 and the inner sidewall 48, and the outer edge 54 may be located at the intersection of the sealing surface 44 and the outer sidewall 50.
The metal face seal 12 is a metallic component and can be formed of any suitable material, such as iron-nickel alloys, iron alloys, carbon steel, and others. Accordingly, and according to an aspect of the disclosure, the sealing surface 44 presents a metallic substrate for receiving a layer of cladding material. For example, metal face seals, such as the metal face seal 12, sometimes receive a layer of comparatively harder metal in a region where the metal face seal contacts another structure. In some embodiments, a preparation process may be performed to prepare the sealing surface 44 for receiving the layer 70 of cladding material.
As shown in
The first and second mold member portions 32, 34 include respective support surfaces 60, 62, and these support surfaces 60, 62 are positioned in substantial alignment with the sealing surface 44. For example, and as shown, the support surfaces 60, 62 may be generally parallel with each other, and may both be positioned so as to be substantially in the same plane as the sealing surface 44. Other configurations are also possible, such as where the support surfaces 60, 62 are inclined relative to each other and/or the sealing surface 44. For example, the support surfaces 60, 62 could be shaped and positioned so as to extend upwardly or downwardly as they extend away from the inner and outer edges 52, 54 of the sealing surface 44. And while the support surfaces 60, 62 are generally planar, other shaped support surfaces could also be used.
As shown, the first mold member portion 32 is positioned such that a space 64 is provided between the first mold member portion 32 and the inner sidewall 48 of the metal face seal 12. Thereby, the support surface 60 of the first mold member portion 32 is spaced a distance from the sealing surface 44 of the metal face seal 12 (in the region of the inner edge 52 of the sealing surface 44). Similarly, the second mold member portion 34 is positioned such that a space 66 is provided between the second mold member portion 34 and the outer sidewall 50 of the metal face seal 12. Thereby, the support surface 62 of the second mold member portion 34 is spaced a distance from the sealing surface 44 of the metal face seal 12 (in the region of the outer edge 54 of the sealing surface 44). Alternatively, either or both of the first and second mold member portions 32, 34 could be positioned such that no space is provided between them and the inner and outer sidewalls 48, 50 of the metal face seal 12. Thus, providing the spaces 64, 66 is optional, and even where such spaces 64, 66 are included, the first and second mold member portions 32, 34 are still considered to be generally adjacent to the metal face seal 12.
The mold member 30 cooperates with the metal face seal 12 during the metal deposition process to control where the melted cladding material feedstock 20 is deposited. As will be explained below, the first and second mold member portions 32, 34 receive a portion of the melted cladding material feedstock 20, and generally obscure the sidewalls 48, 50 of the metal face seal 12. Thereby, the first and second mold member portions 32, 34 generally prevent the melted cladding material feedstock 20 from flowing onto the sidewalls 48, 50.
As shown in
In some embodiments, the metal deposition process is a laser cladding process performed by the laser cladding system 14. During the laser cladding process, the laser device 16 emits a laser beam 18. Cladding material feedstock 20 is positioned generally near the metal face seal 12 and the mold member 30 (including the first and second mold member portions 32, 34). The laser beam 18 heats and melts the cladding material feedstock 20, the metal face seal 12, or both, and melted cladding material feedstock 20 is deposited onto the sealing surface 44 of the metal face seal 12 and the support surfaces 60, 62 of the first and second mold member portions 32, 34 to form the layer 70 of cladding material thereon.
The melted cladding material feedstock 20 is deposited over the entire extent of the sealing surface 44 in the radial direction R, thereby covering the sealing surface 44 between the inner edge 52 and the outer edge 54. In addition, the melted cladding material feedstock 20 is deposited laterally beyond the edges 52, 54 so as to cover portions of the support surfaces 60, 62 of the first and second mold member portions 32, 34. Thereby, the layer 70 of cladding material extends laterally beyond the inner edge 52 where it is deposited onto the support surface 60, and laterally beyond the outer edge 54 where it is deposited onto the support surface 62.
As shown, the cross-section of the layer 70 of cladding material may be generally dome-shaped when it is deposited onto the sealing surface 44 and the support surfaces 60, 62. The shape of the deposited layer 70 may be influenced by several factors, including the surface tension and viscosity of the melted cladding material feedstock 20 as it cools to form the layer 70. A central portion 72 of the layer 70 extends upwardly above the sealing surface 44 between the inner and outer edges 52, 54 of the sealing surface 44. An inner portion 74 of the layer 70 extends laterally beyond the inner edge 52, and an outer portion 76 of the layer 70 extends laterally beyond the outer edge 54. Given this dome shape of the layer 70, the central portion 72 has a generally greater thickness (measured upwardly from the sealing surface 44) than the inner and outer portions 74, 76.
Advantageously, a metallurgical bond is prevented from forming between (1) the melted cladding material feedstock 20 and the layer 70 of cladding material, and (2) the mold member 30. The mold member 30 may be formed of any suitable material, and is advantageously formed of or includes materials for preventing or resisting a metallurgical bond with the melted cladding material feedstock 20 and the layer 70 of cladding material.
In some embodiments, the mold member 30 may include polished metal surfaces that resist forming a metallurgical bond with the melted cladding material feedstock 20 and the layer 70 of cladding material. For example, at least the support surfaces 60, 62 of the first and second mold member portions 32, 34 can be highly polished metal in order to prevent a metallurgical bond from forming when the melted cladding material feedstock 20 is deposited onto the support surfaces 60, 62 during the metal deposition process to form the layer 70. The polished metal surfaces may exhibit a high reflectivity at a wavelength of the laser and therefore resist absorption of the laser light incident thereon. In turn, polished metal surfaces may realize lower temperatures in response to the incident laser light than less polished surfaces of the same metal.
In these or other embodiments, the mold member may include cooled surfaces that resist forming a metallurgical bond with the melted cladding material feedstock 20 and the layer 70 of cladding material. For example, at least the support surfaces 60, 62 of the first and second mold member portions 32, 34 can be cooled in order to prevent a metallurgical bond from forming when the melted cladding material feedstock 20 is deposited onto the support surfaces 60, 62 during the metal deposition process to form the layer 70.
In these or even further embodiments, the mold member 30 may include a contact material that resist forming a metallurgical bond with the melted cladding material feedstock 20 and the layer 70 of cladding material. For example, at least the support surfaces 60, 62 of the first and second mold member portions 32, 34 can include such contact material in order to prevent a metallurgical bond from forming when the melted cladding material feedstock 20 is deposited onto the support surfaces 60, 62 during the metal deposition process to form the layer 70. Suitable contact materials for preventing a metallurgical bond from forming between (1) the melted cladding material feedstock 20 and the layer 70 of cladding material, and (2) the mold member 30 include graphite, ceramics, and polymers.
It will be appreciated that a metallurgical bond between the mold member 30 and the layer 70 of cladding material may be avoided or resisted through careful tailoring of the cladding process. For example, the temperature of the cladding material feedstock 20 and the metal face seal 12 (especially near the sealing surface 44) may be controlled during the cladding process to achieve temperatures that are less than a melting temperature of the mold member 30. Thereby, the mold member 30 is prevented from melting, and from forming a metallurgical bond with the melted cladding material feedstock 20 and the layer 70 of cladding material. The temperature of the metal face seal 12 may be controlled by choice of incident laser power, speed of the laser traversing over the surface of the metal face seal 12, or combinations thereof.
As shown in
As shown in
Optionally, the layer 70 of cladding material may receive further processing to prepare it for its final application. For example, a smoothing process may be performed to impart a substantial smoothness to the layer 70.
The industrial applicability of the methods and system described in this disclosure will be readily appreciated from the foregoing description. The described principles are applicable to a wide range of components and cladding materials. An exemplary component is the metal face seal 12 shown in the figures and described above.
In use, a method of processing a component (the metal face seal 12) includes depositing a layer 70 of cladding material onto both the sealing surface 44 of the metal face seal 12, and onto the support surfaces 60, 62 of the first and second mold member portions 32, 34 of the mold member 30. A metallurgical bond is formed between the cladding material and the metal face seal 12, but not between the cladding material and the first and second mold member portions 32, 34 (which are different from the metal face seal 12).
By not forming a metallurgical bond between the cladding material and the first and second mold member portions 32, 34, the portions 32, 34 can be removed from the metal face seal 12 and from the layer 70 of cladding material, which extends across the entire sealing surface 44. Portions of the layer 70 of cladding material can then be removed to give the layer 70 a desired shape. For example, the portions of the layer 70 that extended laterally beyond the edges 52, 54 can be removed. In some instances, the final shape of the layer 70 of cladding material can have a substantially uniform thickness.
Advantageously, the metal face seal 12 can be a net shape component, meaning that its shape is not further modified, other than where it receives the layer 70 of cladding material. In particular, after the layer 70 of cladding material is formed, only the shape of the layer 70 is modified, and not the shape of the metal face seal 12.
Further, the above-described methods and system are generally applicable to new and used components. For example, a new component may be manufactured to include a layer of cladding material. In addition, an already used component may be remanufactured to include a layer of cladding material.
It will be appreciated that the foregoing description provides examples of the disclosed method and system. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for the features of interest, but not to exclude such from the scope of the disclosure unless specifically indicated.
