Wear components in a laminar structure in a paper of cardboard machine, and the procedure for its production and usage

Abstract

A wear component in a laminar structure, particularly one of a drainage strip, a deflector, a foil or a suction strip in a paper or a cardboard machine, where on at least one of its partial surfaces a medium that causes wear, in particular a fluid or a material web, such as machine clothing in the form of a sieve or a felt in the machine is applied. The wear component including a beam part being made of at least one of plastic, high-grade steel, copper, nickel, aluminum, zinc, and/or an alloy of the foregoing. The wear component also including an infeed area with an infeed angle β for the medium of less than 90° and at least one low-wear layer on at least one of the partial surfaces. The low-wear layer being made of a material from a class of self-fluxing alloys. The low-wear layer being at least partially thermally re-melted.

Description

BACKGROUND OF THE INVENTION

[0002] 1. Field of the invention.

[0003] The invention pertains to a wear component in a laminar structure, and, more particularly to a wear component, in a laminar structure to which is applied, a fluid or a webbed material such as machine clothing.

[0004] 2. Description of the related art.

[0005] Wear components in a laminar structure are used in high-pressure pistons of fluid pumps with a liquid fluid, in high-vacuum pumps with a gas or a mixture of gases, for precision guidance in machine tools and production facilities or as a drainage strip in paper or cardboard machines with the medium of a webbed material in the form of machine clothing.

[0006] Well-known wear components in a paper or cardboard machine, particularly a drainage strip, a deflector, a foil or a suction strip have been produced, from a bonded system, created from sintered ceramic materials and from plastic beams; or from components with applied wear protection layers. The latter version exhibiting a lower thickness as compared to the bonded system.

[0007] The bonded systems are generally produced from sintered ceramic segments that are gummed together or gummed to at least one beam part. The interconnection to the beam is often additionally secured either mechanically or by an adhesive, the connection may also be by way of at least one dovetail groove and, if necessary, with additional screwed joints.

[0008] The ceramic materials that are used, are usually made out of oxides, carbides or nitrides. Such as, the SiC, Si3N4, Al2O3, ZrO2 material groups with various stabilizers, MgO, Y2O3, rare-earth oxides or even multiphase ceramic mixtures made from these compounds.

[0009] The status of the technology in the field of ceramic material wear components in paper or cardboard machines is described in detail in two German patent applications DE 33 06 457 A1 and DE 41 39 105 A1, open to public inspection, in PCT applications WO 92/19565 A1 (=EP 0 588 803 A1), WO 97/10381 A1 and WO 93/00473 A1 and in U.S. Pat. No. 3,393,124. Disadvantages of these predominantly bonded systems result, exist in the usage of comparably expensive, generally difficult to process, sintered ceramic components of above-average expense, production consumption and assembly technique. Additionally, when higher temperatures are applied, as may happen during a dry run of a paper or cardboard machine or due to strong temperature fluctuations, cracks or breaks may be created. As a result, amplified wear takes place on the opposite part, such as machine clothing. Chemical and/or temperature influences lead to adhesive failure on the joints of single ceramic elements, which leads to an increased wear of the machine clothing, if not the destruction of the machine clothing. Moreover, the part's design and the production of sintered ceramic materials limit the free geometric form design of wear components, particularly of drainage elements, such as drainage strips. In addition, the production of infeed areas with infeed angles of <60° is not possible, due to the brittleness of ceramic materials. Another disadvantage is the limited mechanical tolerance to bending and impact stress, which is caused by the brittleness of ceramic materials that leads to disruption of and increased wear of the machine clothing, if not to the destruction of the machine clothing.

[0010] Wear protection layers, such as wear reducing coatings formed on substrates is used, which do not lead to any corrosion due to its properties. The wear protection layers are frequently applied by a thermal spray coating process, since this represents an economical production method, which is not subdivided into segments. According to well-known technique, which, for example, is described in detail in PCT applications WO 96/05370 A1 and WO 96/24717 A1 and in U.S. Pat. Nos. 4,331,511; 3,446,702; 3,778,342; 3,352,749 and 3,351,524. These techniques utilitize coatings from oxides, for example Al2O3, Cr2O3, ZrO2, SiO2 or TiO2, carbides such as WC or TiC, Al- and/or Zr-silicates, borides, for example TiB2, Ti2B, ZrB, ZrB2 or ZrB12 or mixtures of the aforementioned materials or material classes are used.

[0011] A well-known disadvantage of these components, having an applied wear protection layer, is that the limited layer thickness is a maximum 0.5 mm. This limitation is due to the lack of good adhesion resulting from large residual stress within the layers and since there is no mechanical and thermo physical compatibility with the facilitated substrate. As a result the wear cannot be stopped, just slowed. Due to this, the wear components in paper or cardboard machines are inspected, depending on the field of operation, at regular intervals. Another problem, not yet satisfactory resolved at this point, is the porosity of thermally sprayed wear protection layers, which leads to reduced life and increased wear on the machine clothing in a paper or cardboard machine.

[0012] What is needed in the art is an extended life wear protection area that resists wear from fluids and machine clothing.

SUMMARY OF THE INVENTION

[0013] It is the first task of the invention to improve a wear component in a laminar structure, so that it does not possess well-known disadvantages of the current techniques. The present invention has a higher mechanical capacity and allows for more simple handling. Further, it does not contain any segment structure, which results in low wear on the wear component itself and on the medium, particularly at the machine clothing, which may be in the form of a sieve or felt in a paper or cardboard machine. The present invention allows for increased geometric freedom of design and that it is more economical in terms of material costs.

[0014] The second task of the invention is to provide a procedure for the production of a wear component in a laminar structure, which results in a high process certainty, a high production efficiency, high throughput performance and low ongoing procedure costs.

[0015] The first task, in accordance with an embodiment of the present invention is resolved for the wear component in a laminar structure in that the wear component in a laminar structure is formed from one beam. The beam being made out of high-grade steel and/or copper and/or nickel and/or pressure die-cast aluminum and/or zinc, and/or at least from one of their alloys. Alternatively, the beam may be made from a plastic beam with at least one inserted plate made out of high-grade steel and/or copper and/or nickel and/or aluminum and/or zinc and/or at least from one of their alloys. The wear component in the laminar structure has an infeed area with an infeed angle for a medium of <90°, preferably <45°. At least one partial surface of the wear component in the laminar structure that is subject to wear, has at least one low-wear layer, made from a material of the class of the self-fluxing alloys and that the low-wear layer was re-melted thermally.

[0016] This wear component in a laminar structure, does not contain any disadvantageous segment structures. Due to the thermal re-melting process there is a diffusion connection between the beam part (basic material) and the applied low-wear layer (wear protection layer) with improved bonding strength in comparison to other thermal spray layers. This provides a higher mechanical capacity, allowing for simple handling and results in a reduced wear on the medium, particularly to the machine clothing, which may be in the form of a sieve or felt in a paper or cardboard machine. Moreover, the geometric freedom of design provides for the opportunity to realize, in the infeed area of the drainage elements in a paper or cardboard machine, infeed angles of <60°, which results in improved drainage performance.

[0017] In order to further enhance the wear properties of the low-wear layer and to further improve its life, there is at least one hard material added to the self-fluxing alloy for the creation of the low-wear layer. Based on production and cost criteria, the low-wear layer is preferably made out of a self-fluxing alloy, such as, NiCrB, NiCrBSi, CoNiCrBSi, mixtures of these alloys or another self-fluxing alloy. The hard material, includes at least one oxide, particularly Al23, Cr2O3, ZrO2, SiO2 or TiO2 and/or a carbide, particularly WC or TiC, and/or a boride, particularly TiB2, Ti2B, ZrB, ZrB2 or ZrB12, and/or a silicide and/or a mixture of the above-mentioned materials and material classes. Additionally, elements such as Fe, C or Mo may be added to the low-wear layer.

[0018] It is advantageous, if the low-wear layer has a re-melted layer thickness ranging from 0.5 mm to 2 mm and preferably from 0.75 mm to 1.5 mm. The layer thickness is reasonable in terms of cost and can be produced with a process that secures it to the beam and corresponds with practical requirements. In order to keep the wear properties of the medium, particularly with the machine clothing, which may be in the form of a sieve or felt in a paper or cardboard machine, as low as possible, the low-wear layer has a porosity from 0% to 10%, preferably from 0.3% to 5%.

[0019] The wear properties of the wear component in the laminar structure, in accordance with the present invention, are reduced or minimized as much as possible. The low-wear layer has a surface finish Ra from 0.01 μm to 10 μm, preferably from 0.01 μm to 1 μm, a surface finish Rz from 0.1 μm to 10 μm, preferably from 0.5 μm to 1 μm. The low-wear layer has a hardness HU 1.0 from 3,006 N/mm2 to 15,000 N/mm2, preferably from 5,000 N/mm2 to 10,000 N/mm2, a layer hardness H plast from 5,000 N/mm2 to 30,000 N/mm2, preferably from 5,500 N/mm2 to 20,000 N/mm2, and/or a layer hardness HV 0.1 from 650 to 5,000, preferably from 700 to 2,500. These parameters provide a selection of wear reducing and minimizing data and can be realized separately or in combination.

[0020] In regards to the wear component in the laminar structure, it is advantageous if its low-wear layer exhibits a length expansion coefficient α from 20° C. to 250° C., of 8·10−6K−1 to 9·10−6K−1 since these parameters are sufficient for the thermal requirements in the machines mentioned. Moreover, expansion coefficient α lies between the corresponding parameters of steel and of ceramics, such as Al2O3.

[0021] The firmness and the technical wear properties of the wear component, in accordance with another embodiment of the present invention, is further improved if the low-wear layer is applied to the surface areas, which border a partial surface that is subject to wear, particularly at the infeed area. Exemplarily, the complete infeed area is coated including all areas associated with the infeed angle and the drainage strip, in a paper or cardboard machine.

[0022] The second task, in accordance with an embodiment of the present invention, is resolved in a way such that the wear component in a laminar structure is preferably created from a single beam part, out of high-grade steel and/or copper and/or nickel and/or pressure die-casting and/or aluminum and/or zinc and/or at least one of their alloys. Alternatively, a plastic beam may be utilized with at least one inserted plate made out of high-grade steel and/or copper and/or nickel and/or aluminum and/or zinc and/or at least one of their alloys, so that at least one partial surface of the wear component in a laminar structure, that is subject to wear, has at least one low-wear layer. The low-wear layer being made from material of a self-fluxing alloys, which was added by a thermal spray coating process and the low-wear layer is thermally re-melted. By doing so, a high degree of process certainty and runability is inherent with the present invention. Moreover, the present invention lowers procedure costs and requires a lower investment.

[0023] In order to further enhance the wear properties of the low-wear layer and to improve its life, at least one hard material is added to the self-fluxing alloy in order to create the low-wear layer during the thermal spray coating process. Based on procedural and economical criteria, the self-fluxing alloy is applied to the wear component in a laminar structure by high-speed flame spraying (HVOF), by flame spraying, by a plasma procedure or by an autogenous procedure. The procedures result in high quality properties of the created low-wear layer.

[0024] The thermal re-melting process is preferably performed by at least one burner and/or with at least one laser beam and/or with at least one arc and/or with several high-power lamps and/or with at least one oven coalescence and/or with at least one induction heater. These procedures and devices are each characterized by good techniques as well as profitability.

[0025] The firmness and the technical wear properties of the wear component, in accordance with the present invention, is further improved if the low-wear layer is applied to the surface areas, which border a partial surface that is subject to wear, particularly at the infeed area. Exemplarily, the coating is applied to the complete infeed area, including all areas associated with the infeed angle and the drainage strip, in a paper or cardboard machine.

[0026] It is advantageous if the low-wear layer has a re-melted layer thickness from 0.5 mm to 2 mm, and preferably from 0.75 mm to 1.5 mm. The layer thickness is reasonable in terms of cost and can be produced with a process that secures it to the beam and corresponds with practical requirements.

[0027] In accordance with another embodiment of the present invention, a procedure for the drainage and/or formation of a fibrous material suspension is also proposed, where machine clothing, particularly a sieve or felt of a paper or cardboard machine, is present above a wear component in a laminar structure which is in accordance with the invention.

[0028] It is clear that the features of the present invention, named hereinabove and to be further explained, are applicable not only in their mentioned combinations but in other combinations, too, as well as in single usage which is still the subject of this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0030] FIG. 1 illustrates a cross-sectional side view of a first wear component in a laminar structure in accordance with one embodiment the present invention;

[0031] FIG. 2 illustrates a cross-sectional side view of another wear component in a laminar structure in accordance with an embodiment of the present invention;

[0032] FIG. 3 illustrates a micrograph of the wear components in a laminar structure in accordance with the present invention; and

[0033] FIG. 4 illustrates a micrograph of the wear components in a laminar structure in accordance with the present invention.

[0034] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

[0035] Referring now to the drawings and more particularly to FIG. 1 there is a side view of a first wear component 1 in a laminar structure in accordance with the invention. Wear component 1 in a laminar structure is represented by a drainage strip 2 of a paper or cardboard machine (not displayed). In this machine there is at least one partial surface 3, which is subject to wear caused by machine clothing 4, such as medium 4.1 in the form of a sieve 5. Wear component 1 is formed from one beam part 6 out of high-grade steel 6.1 and/or copper and/or nickel and/or pressure die-casting and/or aluminum and/or zinc and/or at least from one of their alloys. Wear component 1 has an infeed area 7 with an infeed angle B for machine clothing 4 and medium 4.1, collectively referred to as fiber medium, of <90°, preferably <45°. At least one partial surface 3 of wear component 1 that is subject to wear, has at least one low-wear layer 9, made from a material of at least one of self-fluxing alloys 8 and low-wear layer 9 is thermally re-melted. The re-melting process results in the metallurgical bonding of the layers.

[0036] It is advantageous if low-wear layer 9 contains either NiCrB, NiCrBSi, CoNiCrBSi or at least one additional self-fluxing alloy 8 and provides a re-melted layer thickness A from 0.5 mm to 2 mm, and preferably from 0.75 mm to 1.5 mm and a porosity P of 0% to 10%, and preferably from 0.3% to 5%. Additional elements, such as Fe, C or Mo, may be added to low-wear layer 9.

[0037] In addition, low-wear layer 9 has a surface finish Ra from 0.01 μm to 10 μm, preferably from 0.01 μm to 1 μm, a surface finish Rz from 0.1 μm to 10 μm, preferably from 0.5 μm to 10 μm. Low-wear layer 9 has a hardness HU 1.0 of from 3,000 N/mm2 to 15,000 N/mm2, preferably from 5,000 N/mm2 to 10,000 N/mm2, a layer hardness H plast of from 5,000 N/mm2 to 30,000 N/mm2, preferably from 5,500 N/mm2 to 20,000 N/mm2, and/or a layer hardness HV 0.1 of from 650 to 5,000, preferably from 700 to 2,500. Low-wear layer 9 has a length expansion coefficient a from 20° C. to 250° C., of 8·10−6K1 to 9·10−6K−1. Low-wear layer 9 has at least one hard material 10 added to self-fluxing alloy 8, which contains at least one oxide, particularly from Al2O3, Cr2O3, ZrO2, SiO2 or TiO2 and/or carbides, such as WC or TiC, and/or boride, particularly from TiB2, Ti2B, ZrB, ZrB2 or ZrB12 and/or a silicide and/or mixtures of these materials or material classes.

[0038] Now, additionally referring to FIG. 2, there is shown a side view of another embodiment of wear component 1 in accordance with the present invention in a laminar structure, similar to FIG. 1. According to this embodiment of the invention, wear component 1 is preferably formed from one beam part 6 made out of plastic beam 6.2 with at least one inserted plate 6.3 made out of high-grade steel 6.1 and/or copper and/or nickel and/or pressure die-casting and/or aluminum and/or zinc and/or from at least one of their alloys. Low-wear layer 9 is also applied to surface areas 3.1, which borders partial surface 3 that is subject to wear, particularly at infeed area 7.

[0039] Now, additionally referring to FIGS. 3 and 4, there is shown two micrographs of wear component 1 in a laminar structure in accordance with the invention at two different magnification scales. Low-wear layer 9 contains NiCrBSi.

[0040] A procedure in accordance with the present invention results in the production of wear components with a laminar structure. The present invention creates a wear component with a laminar structure in accordance with the procedures that are described herein, which has a higher mechanical capacity and allows for more simple handling than the prior art. The present invention does not contain any segment structure, which results in a low wear tolerance on the wear component itself and on the medium, particularly on the machine clothing, which is in the form of a sieve or the felt in a paper or cardboard machine; and that it allows for increased geometric freedom of design and is more economical in terms of material costs.

[0041] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Claims

1. A machine for the production of a fiber web including a wear component for at least a partial surface of a friction body to which a fiber medium is applied, said wear component comprising: a beam part comprised of a metal selected from the group consisting of high-grade steel, copper, nickel, aluminum, zinc, and an alloy of the foregoing; an infeed area with an infeed angle β for the medium of less than 90°; and at least one low-wear layer on the friction body, said at least one low-wear layer being made of a material from a class of self-fluxing alloys, said low-wear layer being at least partially thermally re-melted.

2. The wear component of claim 1, further comprising an other beam part comprised of plastic having at least one plate inserted therein, said plate comprised of said selected metal.

3. The wear component of claim 1, wherein said infeed angle β is <45°.

4. The wear component of claim 1, wherein said self-fluxing alloys include at least one of NiCrB, NiCrBSi, CoNiCrBSi and an additional self-fluxing alloy.

5. The wear component of claim 4, wherein said low-wear layer additionally includes at least one hard material added to said self-fluxing alloy.

6. The wear component of claim 5, wherein said low-wear layer additionally includes at least one of Fe, C and Mo.

7. The wear component of claim 4, wherein said at least one hard material contains at least one of an oxide including at least one of Al2O3, Cr2O3, ZrO2, SiO2 and TiO2, a carbide including at least one of WC and TiC, a boride including at least one of TiB2, Ti2B, ZrB, ZrB2 and ZrB12, and a silicide.

8. The wear component of claim 1, wherein said low-wear layer includes a re-melted layer having a thickness of from approximately 0.5 mm to approximately 2 mm.

9. The wear component of claim 8, wherein said thickness is from approximately 0.75 mm to approximately 1.5 mm.

10. The wear component of claim 1, wherein said low-wear layer has a porosity of from approximately 0% to approximately 10%

11. The wear component of claim 10, wherein said porosity is from approximately 0.3% to approximately 5%.

12. The wear component of claim 1, wherein said low-wear layer has a surface finish Ra from approximately 0.01 μm to approximately 10 μm.

13. The wear component of claim 12, wherein said surface finish Ra is from approximately 0.01 μm to approximately 1 μm.

14. The wear component of claim 1, wherein said low-wear layer has a surface finish Rz of from approximately 0.1 μm to approximately 10 μm.

15. The wear component of claim 14, wherein said surface finish Rz is from approximately 0.5 μm to approximately 1 μm.

16. The wear component of claim 1, wherein said low-wear layer has a hardness HU 1.0 of from approximately 3,000 N/mm2 to approximately 15,000 N/mm2.

17. The wear component of claim 16, wherein said hardness HU 1.0 is from approximately 5,000 N/mm2 to approximately 10,000 N/mm2.

18. The wear component of claim 1, wherein said low-wear layer has a hardness H plast of from approximately 5,000 N/mm2 to approximately 30,000 N/mm2.

19. The wear component of claim 18, wherein said hardness H plast is from approximately 5,500 N/mm2 to approximately 20,000 N/mm2.

20. The wear component of claim 1, wherein said low-wear layer has a hardness HV 0.1 of from approximately 650 to approximately 5,000.

21. The wear component of claim 20, wherein said hardness HV 0.1 is from approximately 700 to approximately 2,500.

22. The wear component of claim 1, wherein said low-wear layer has a length expansion coefficient from 20° C. to 250° C., of from approximately 8*10−6 K−1 to approximately 9*10−6 K−1.

23. The wear component of claim 1, wherein said low-wear layer is additionally applied to at least one surface area which borders the at least one partial surface, said at least one surface area including said infeed area.

24. A procedure for the production of a wear component in a paper machine, where on at least one partial surface of the wear component a medium that causes wear is applied, the procedure comprising the steps of: forming a beam part comprised of a metal selected from the group of high-grade steel, copper, nickel, aluminum, zinc, and an alloy of the foregoing; thermal spray coating at least one low-wear layer onto the at least one partial surface of the wear component, said low-wear layer made of a material from a class of self-fluxing alloys; and thermally re-melting at least a portion of said low-wear layer.

25. The procedure of claim 24, further comprising the step of inserting a plate comprised of said selected metal into an other beam part, said other beam part comprised of plastic.

26. The procedure of claim 24, wherein said material further includes at least one hard material added during said thermal spray coating step to said self-fluxing alloy for the creation of said low-wear layer.

27. The procedure of claim 24, wherein said thermal spray coating step comprises the step of high-speed flame spraying (HVOF), by one of flame spraying, a plasma procedure and an autogenous procedure to create said low-wear layer.

28. The procedure of claim 24, wherein said thermal re-melting step is performed with at least one of at least one burner, at least one laser beam, at least one arc, several high-power lamps, at least one coalescence oven and at least one induction heater.

29. The procedure of claim 24, wherein said thermal spray coating step applies said low-wear layer to surface areas which border the at least one partial surface.

30. The procedure of claim 24, wherein said low-wear layer is applied with a re-melted layer thickness of from approximately 0.5 mm to approximately 2 mm.

31. The procedure of claim 30, wherein said thickness is from approximately 0.75 mm to approximately 1.5 mm.

32. The procedure of claim 24, further comprising the step of forming a fibrous material suspension where machine clothing in the form of one of a sieve and a felt is positioned proximate to the wear component.