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US 2013/0196169 A1Published application
Wear Resistant Material and System and Method of Creating A Wear Resistant Material
AssigneeESCO Corporation
InventorSrinivasarao Boddapati
Life of this patent
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Abstract
A system and method of forming a wear resistant composite material includes placing a porous wear resistant filler material in a mold cavity and infiltrating the filler material with a matrix material by heating to a temperature sufficient to melt the matrix material, then cooling the assembly to form a wear resistant composite material. The system and method can be used to form the wear resistant composite material on the surface of a substrate, such as a part for excavating equipment or other mechanical part. One suitable matrix material may be any of a variety of ductile iron alloys.
Claims65
A method comprising:
- positioning a mold proximate a surface of a substrate, such that the surface is in communication with a cavity of the mold;
- placing a porous wear resistant material within the cavity, in close proximity to the surface;
- placing a metallic matrix material in communication with the cavity, wherein the matrix material comprises ductile iron;
- heating the mold and the matrix material to a temperature above a melting point of the matrix material and holding the temperature above the melting point for a time sufficient for the matrix material to infiltrate the wear resistant material in molten form and contact the surface of the substrate;
- cooling the mold and the matrix material to solidify the matrix material and form a wear resistant composite coating comprising the wear resistant material embedded within the matrix material on the surface of the substrate.
2 more elements
A system comprising:
- a substrate having a surface;
- a mold positioned in proximity to the surface of the substrate, such that the surface is in communication with a cavity of the mold;
- a porous wear resistant material within the cavity, in close proximity to the surface;
- and
- a metallic matrix material in communication with the cavity, wherein the matrix material comprises ductile iron;
- wherein the system is configured for:
- heating the mold and the matrix material to a temperature above a melting point of the matrix material and holding the temperature for a time sufficient for the matrix material to infiltrate the wear resistant material in molten form and contact the surface of the substrate;
- cooling the mold and the matrix material to solidify the matrix material and form a wear resistant composite coating on the surface of the substrate.
5 more elements
An article of manufacture comprising:
- a metallic substrate having a surface with a wear resistant composite coating bonded to the surface, wherein the wear resistant composite coating comprises:
- a porous wear resistant material;
- a metallic matrix material intermixed with the wear resistant material, the matrix material further being bonded to the surface of the substrate to bond the wear resistant composite coating to the substrate, wherein the metallic matrix material comprises ductile iron.
A wear member for earthmoving equipment comprising a working portion and a composite coating overlaying the working portion, the coating comprising a porous wear resistant material and a ductile iron matrix material intermixed with the wear resistant material, wherein the matrix material bonds the coating to the working portion.
A method comprising:
- positioning a mold proximate a surface of a substrate to define a cavity;
- placing a porous wear resistant material within the cavity;
- placing a metallic matrix material in communication with the cavity;
- melting the matrix material to form a molten matrix material, by heating within a furnace chamber to a temperature above a melting point of the matrix material, wherein the melting is performed in a vacuum;
- holding the temperature above the melting point until the molten matrix material infiltrates the wear resistant material;
- cooling the matrix material to solidify the molten matrix material and form a wear resistant composite coating comprising the wear resistant material embedded within the matrix material on the surface of the substrate.
3 more elements
A method comprising:
- positioning a mold proximate a surface of a substrate to define a cavity, wherein the mold has a permeable portion;
- placing a porous wear resistant material within the cavity, such that the permeable portion is in contact with the wear resistant material;
- placing a metallic matrix material in communication with the cavity;
- melting the matrix material to form a molten matrix material, by heating within a furnace chamber to a temperature above a melting point of the matrix material, in the presence of an inert gas;
- holding the temperature above the melting point until the molten matrix material infiltrates the wear resistant material, wherein residual gas within the wear resistant material can escape through the permeable portion;
- cooling the matrix material to solidify the molten matrix material and form a wear resistant composite coating comprising the wear resistant material embedded within the matrix material on the surface of the substrate.
3 more elements
A method comprising:
- positioning a mold proximate a surface of a substrate to define a cavity;
- placing a porous wear resistant material within the cavity;
- placing a metallic matrix material in communication with the cavity, wherein the matrix material is positioned laterally to the wear resistant material;
- placing a displacement medium adjacent the matrix material, opposite the wear resistant material;
- melting the matrix material to form a molten matrix material, by heating to a temperature above a melting point of the matrix material;
- holding the temperature above the melting point until the molten matrix material infiltrates the wear resistant material, wherein the displacement medium supports the molten matrix material and displaces the molten matrix material as the molten matrix material infiltrates the wear resistant material;
- cooling the matrix material to solidify the molten matrix material and form a wear resistant composite coating comprising the wear resistant material embedded within the matrix material on the surface of the substrate.
4 more elements
Dependencies are inferred from the claim text.