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Patent Analysis of

Thermal spray composition and component made therewith

Updated Time 12 June 2019

Patent Registration Data

Publication Number

US10000839

Application Number

US15/162767

Application Date

24 May 2016

Publication Date

19 June 2018

Current Assignee

CATERPILLAR INC.

Original Assignee (Applicant)

CATERPILLAR INC.

International Classification

B32B15/00,C23C4/08,C23C4/126,C22C38/02,C22C38/04

Cooperative Classification

C23C4/08,C22C38/02,C22C38/04,C22C38/06,C22C38/16

Inventor

SORDELET, DANIEL

Abstract

Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.

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Claims

1. A thermal spray coating composition comprising about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron.

2. The thermal spray coating composition of claim 1, wherein the copper is about 2% to about 12% by weight.

3. The thermal spray coating composition of claim 1, wherein the aluminum is about 8% by weight.

4. The thermal spray coating composition of claim 1, wherein the silicon is about 6% by weight silicon.

5. The thermal spray coating composition of claim 1, wherein the manganese is about 2% by weight.

6. The thermal spray coating composition of claim 1, wherein the copper is about 2% by weight.

7. The thermal spray coating composition of claim 1, wherein the copper is about 6% by weight.

8. The thermal spray coating composition of claim 1, wherein the copper is about 12% by weight.

9. The thermal spray coating composition of claim 1, wherein the thermal spray coating can be used in one or more of the following processes: plasma spraying, detonation spraying, twin wire arc spraying, flame spraying, or high velocity oxy-fuel coating spraying.

10. The thermal spray coating composition of claim 1, wherein the thermal spray coating composition is a wire.

11. The thermal spray coating composition of claim 9, wherein the wire is a cored wire.

12. The thermal spray coating composition of claim 1, wherein the thermal spray coating composition is gas atomized powder.

13. A remanufactured component comprising a substrate and a thermal spray coating composition comprising about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 2% to about 12% copper, with a remaining balance of iron.

14. The remanufactured component of claim 13, wherein the thermal spray coating composition is a wire.

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Claim Tree

  • 1
    1. A thermal spray coating composition comprising
    • about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron.
    • 2. The thermal spray coating composition of claim 1, wherein
      • the copper is about 2% to about 12% by weight.
    • 3. The thermal spray coating composition of claim 1, wherein
      • the aluminum is about 8% by weight.
    • 4. The thermal spray coating composition of claim 1, wherein
      • the silicon is about 6% by weight silicon.
    • 5. The thermal spray coating composition of claim 1, wherein
      • the manganese is about 2% by weight.
    • 6. The thermal spray coating composition of claim 1, wherein
      • the copper is about 2% by weight.
    • 7. The thermal spray coating composition of claim 1, wherein
      • the copper is about 6% by weight.
    • 8. The thermal spray coating composition of claim 1, wherein
      • the copper is about 12% by weight.
    • 9. The thermal spray coating composition of claim 1, wherein
      • the thermal spray coating can be used in one or more of the following processes: plasma spraying, detonation spraying, twin wire arc spraying, flame spraying, or high velocity oxy-fuel coating spraying.
    • 10. The thermal spray coating composition of claim 1, wherein
      • the thermal spray coating composition is a wire.
    • 12. The thermal spray coating composition of claim 1, wherein
      • the thermal spray coating composition is gas atomized powder.
  • 13
    13. A remanufactured component comprising
    • a substrate and a thermal spray coating composition comprising about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 2% to about 12% copper, with a remaining balance of iron.
    • 14. The remanufactured component of claim 13, wherein
      • the thermal spray coating composition is a wire.
See all independent claims <>

Description

TECHNICAL FIELD

The present disclosure relates to thermal spray coating compositions, and more specifically, to thermal spray coating compositions for remanufactured components.

BACKGROUND

Manufacturing new components can be extremely expensive, accordingly, engineers are constantly seeking ways to refurbish or remanufacture used components to match technical and dimensional specifications for the component as new. For instance, in the engine industry there is a continuous effort to find new and more economical ways to remanufacture components, such as engine blocks and engine heads. Remanufacturing metallic components often requires adding material to the used body to build up a surface that no longer satisfies a dimensional specification for the component. For instance, in the case of an engine block, the distance between the head face and a centerline of a crank shaft support bore may have slightly decreased over the life of the used block. Therefore, in order to remanufacture the engine block, the head face needs to have material added, and then the treated component often needs to be reshaped by removing some of the added material to return all dimensions to specification.

Many different techniques for remanufacturing a component exist, however, the newly added material often also must exhibit characteristics that match or exceed the metallic material of the original component. For instance, in the case of an engine head or engine block, the added material must successfully undergo many cycles of being heated from ambient temperature to combustion temperatures on the order of about 700° C., be exposed to corrosive gases, and do so without degradation on par with the base metallic material, which may be steel or cast iron. Apart from these considerations, cost of the added material can be a constraint as well as the ability of the added material to be machined back into specification. Thus, finding a technique to add the material, and finding an appropriate metallic material for addition in a remanufacturing procedure while satisfying many different and often conflicting constraints, including cost, can be extremely elusive.

The present disclosure is directed toward one or more of the problems set forth above.

SUMMARY OF THE INVENTION

In one aspect, the present disclosure is related to a thermal spray coating composition comprising about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. In one embodiment, the copper content is about 2% to about 12% by weight. Specifically, for example, the copper can be about 2% by weight, about 6% by weight, or about 12% by weight.

The thermal spray coating composition can include about 8% aluminum by weight. The thermal spray coating composition can include about 6% silicon by weight silicon. The thermal spray coating composition can include about 2% manganese by weight.

The thermal spray coating composition can be used in one or more of the following processes: plasma spraying, detonation spraying, twin wire arc spraying, flame spraying, or high velocity oxy-fuel coating spraying. The thermal spray coating composition can be a wire, for example, a cored wire. The thermal spray coating composition can be gas atomized powder.

In another aspect, the present disclosure relates to a method of remanufacturing a component including applying a thermal spray coating composition to a substrate, wherein the thermal spray coating composition comprises about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron; and cooling the thermal spray coating composition rapidly. In one embodiment, the thermal spray coating composition includes about 2% to about 12% by weight copper.

The method can be applied by a process selected from the following: plasma spraying, detonation spraying, twin wire arc spraying, flame spraying, or high velocity oxy-fuel coating spraying.

The thermal spray coating composition can be a wire, for example, a cored wire. The thermal spray coating composition can be gas atomized powder.

In still another aspect, the present disclosure relates to a remanufactured component including a substrate and a thermal spray coating composition including about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 2% to about 12% copper, with a remaining balance of iron. The thermal spray coating composition can be a wire.

DETAILED DESCRIPTION

This disclosure relates to components, compositions, and methods for manufacturing machine components via a thermal spray coating process. Machines, such as track type tractors or excavators, include components that are subject to wear. Compositions have been developed to repair or restore those worn components. The disclosed compositions can be applied to a wide range of components that receive a layer of material to provide a new surface.

Many different components, particularly engine components, can be remanufactured and returned to service for a second useful life that may even exceed the useful life of a newly manufacture component. Parts that may be subject to remanufacture include, but are not limited to, engine heads, engine blocks, shafts, oil coolers, pump/turbo/engine housings, covers, intake/exhaust fittings, crankshafts, wheel spindles, rail car axles, brake anchors, and many others.

A used component will have a shape resulting from use, which may be attributed to at least one of wear and/or degradation, and removal of additional material from the component to properly prepare a surface for remanufacturing. For instance, it might be desirable to remove some of the original metallic material so that the resulting coating, after being milled, has some minimum thickness. In any event, the shape of the body will include at least one dimension that does not match the dimensional specification for the component.

The disclosed composition can be applied using a thermal spray process. Specifically, the thermal spray process can include a process selected from the following: plasma spraying, detonation spraying, twin wire arc spraying, flame spraying, or high velocity oxy-fuel coating spraying.

The thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. In one embodiment, the thermal spray coating composition can include about 2% to about 12% by weight copper. For example, the thermal spray coating composition can include about 2% copper by weight, about 6% copper by weight, or about 12% copper by weight.

The thermal spray coating composition can include about 8% by weight aluminum. The thermal spray coating composition can include about 6% by weight silicon. The thermal spray coating composition can include about 2% by weight manganese.

In one embodiment the thermal spray coating composition can be supplied during the thermal spray process as a wire, for example, as a cored wire. In another embodiment, the thermal spray coating composition can be gas atomized powder.

In another aspect, the present disclosure relates to a method of remanufacturing a component including applying a thermal spray coating composition to a substrate and cooling the thermal spray coating composition rapidly. The thermal spray coating composition can include about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. In one embodiment, the thermal spray coating composition can include about 2% to about 12% by weight copper. For example, the thermal spray coating composition can include about 2% copper by weight, about 6% copper by weight, or about 12% copper by weight.

The thermal spray coating composition can include about 8% by weight aluminum. The thermal spray coating composition can include about 6% by weight silicon. The thermal spray coating composition can include about 2% by weight manganese.

The thermal spray coating composition can be applied by a process selected from the following: plasma spraying, detonation spraying, twin wire arc spraying, flame spraying, or high velocity oxy-fuel coating spraying.

The thermal spray coating composition can be supplied during the thermal spray process as a wire, for example, a cored wire. The thermal spray coating composition can also be supplied during the thermal spray process as gas atomized powder.

After the thermal spray coating composition is applied, the component can be subjected to a heat treatment process. For example, the component can be heated to about 800° Celsius (C) for 24 hours.

The term “about” means a number rounded to the nearest significant digit. Thus, 749° C. is about 700° C., but 760° C. is not about 700° C.

EXAMPLE

The following example is for illustrative purposes only. The following compositions were deposited onto a substrate using a thermal spray process. Each of the compositions was machined using the same tools and the surface roughness was measured. Surface roughness is highly dependent upon the particular technique and machine used. It is believed that surface roughness may correlate to machinability of the composition.


Compo-
Compo-
Compo-
Compo-
Element
sition 1
sition 2
sition 3
sition 4
Aluminum
8%
8%
8%
8%
Silicon
6%
6%
6%
6%
Manganese
0%
2%
2%
2%
Copper
0%
2%
6%
12% 
Iron
Balance
Balance
Balance
Balance

The surface roughness of the composition 1 was 2.4 microns, composition 2 was 1.6 microns, composition 3 was 1.0 microns, and composition 4 was about 0.7 microns. A lower surface roughness generally correlates to a higher machinability. Accordingly, the increased copper concentrations showed increased machinability.

It is believed that adding face-centered cubic (fcc) transition metal elements, such as copper, that are insoluble in a body-centered cubic (bcc) iron matrix increases the machinability of the composition due to the uniform distribution of the fcc crystal structure phase. Moreover, it is believed that the rapid solidification that occurs during thermal spray deposition unexpectedly aided in achieving a very uniform distribution of copper within the iron matrix. In other words, it is believed that the molten droplets formed during thermal spraying solidified so quickly upon impact that the insoluble copper does not have time to segregate to their thermodynamically-stable condition as coarser, separate phases.

INDUSTRIAL APPLICABILITY

The present disclosure finds potential applicability in any remanufacture strategy where there is a desire for at least one of reducing cost of the coating material or improving efficiency with regard to the application and machining of the coating. The present disclosure finds specific application in substituting the disclosed thermal spray coating composition of the present disclosure in place of the material used in the past to remanufacture components.

The thermal spray coating composition of the present disclosure can be applied to a new part to increase wear and corrosion resistance or to a used part to bring the used part into specification for reuse. The used part may have a wear area that requires additional material, such as the disclosed thermal spray coating composition. The used part, or a remanufactured component, can include a substrate and a thermal spray coating composition including about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 2% to about 12% copper, with a remaining balance of iron. The substrate is usually the original material that has worn away during use of the component. The thermal spray coating composition provides the remanufactured component with the material to restore the worn area.

For example, the thermal spray coating composition can be applied to a worn component to return the component to its original dimensions. The thermal spray coating composition can be applied repeatedly to build up the wear area, depending on the level of wear. The thermal spray coating composition, therefore, can restore the remanufactured component to the same dimensions as the original component.

It will be apparent to those skilled in the art that various modification and variations can be made to the disclosed composition, method, and remanufactured component. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed composition. It is intended that the specification and example be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.

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Patent Valuation

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25.0/100 Score

Market Attractiveness

It shows from an IP point of view how many competitors are active and innovations are made in the different technical fields of the company. On a company level, the market attractiveness is often also an indicator of how diversified a company is. Here we look into the commercial relevance of the market.

31.0/100 Score

Market Coverage

It shows the sizes of the market that is covered with the IP and in how many countries the IP guarantees protection. It reflects a market size that is potentially addressable with the invented technology/formulation with a legal protection which also includes a freedom to operate. Here we look into the size of the impacted market.

74.0/100 Score

Technology Quality

It shows the degree of innovation that can be derived from a company’s IP. Here we look into ease of detection, ability to design around and significance of the patented feature to the product/service.

61.0/100 Score

Assignee Score

It takes the R&D behavior of the company itself into account that results in IP. During the invention phase, larger companies are considered to assign a higher R&D budget on a certain technology field, these companies have a better influence on their market, on what is marketable and what might lead to a standard.

21.0/100 Score

Legal Score

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Citation

Patents Cited in This Cited by
Title Current Assignee Application Date Publication Date
一种用于刀具的耐高温合金涂层及其制备方法 南京腾达五金制品有限公司 07 September 2015 16 December 2015
Titanium-containing ferrous hard-facing material source and method for hard facing a substrate LIQUIDMETAL COATINGS, LLC 31 May 1995 09 December 1997
Process for producing doubly oriented cube-on-face magnetic sheet material WESTINGHOUSE ELECTRIC CORPORATION 28 January 1965 11 October 1966
Iron-chromium-molybdenum-based thermal spray powder and method of making of the same CRUCIBLE INTELLECTUAL PROPERTY, LLC 18 March 2011 28 February 2013
Composite Metal Alloy Material THE REGENTS OF THE UNIVERSITY OF MICHIGAN,FORD GLOBAL TECHNOLOGIES, LLC 31 October 2013 30 April 2015
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