Patent Application
20170211187
In the business of metal plating, relating to the rebuilding of bearing components, many techniques have come and gone. Any of these processes can be used with our nucleated plating. We enhance whatever you do for your application.
We've discovered that by adjustment in the pre and post bake process, we can eliminate the diffusion zone, thereby enhancing the bonding of the rebuild. Do to the various properties of all the metals used in commercial, military and aerospace applications the numbers vary drastically. Although our process is unique in end of itself, testing would be endless. The proper numbers for the pre and post bake process can only be determined when both metals are known.
For the purpose of this specification dialogue we can say 300° to 500° on the prebake and 550° −800° post bake.
In the realm of rebuilding bearing surface for high speed applications, i.e. jet turbines, the industry has admitted to an inordinate amount of plating failures. These failures can and have led to catastrophic failures.
Our process, Revised Nucleated Plating, eliminates the diffusion zone that can cause this failure.
With the “Revised Nucleated Plating” process eliminating the diffusion zone, we have also created an environment by which you have enhanced bonding and an ability for minor flex and better ability to handle shock impacts on bearings and after more discussion we began looking at the process by which the plating takes place.
With all of the variables conspiring to derail the plating process, i.e. impurities in the 2 metals, dirty air in the plating room where the process is being done, dirty or worn out chemicals, not to mention the attitude of the operator, impurities that are inherit in most metal causing the “Kirkendall Effect”, we needed a simple fix.
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Item #1—Shows the electro less Nickel Plating
Item #2—The bonding line of the two metals
Item #3—The 4130 base metal
As seen in the photo there isn't any sign of a diffusion zone.
This photo was at 10,000× on S.E.M.
Photo “Diffusion Zone #1 shows a very define diffusion zone often found on plated metals
With the cost associated with the purchase of new equipment in commercial and military applications rising constantly, the Acquisition Specialists are always looking for cost cutting; this has led to the rebuilding of worn units.
A major hurdle has always been the bearing races, the higher the load, rpm and vibration, the more app of the rebuilt bearing race to fail.
With this being a very real problem in gas turbines leading to catastrophic ground sky interdiction with helicopters, some companies are shying away from rebuilds.
After extended Q & A and much research and addition discussions we began looking at the process by which the plating takes place.
With all of the variables conspiring to derail the plating process, i.e. impurities in the 2 metals, dirty air in the plating room where the process is being done, dirty or worn out chemicals, not to mention the attitude of the operator, impurities that are inherit in most metal causing the “Kirkendall Effect”, we needed a simple fix.
We discovered a major break thru in bonding of the 2 metals. By careful manipulation of the prebake and post bake during the process can eliminate the diffusion zone between the parent and applied metals.
