US20110259541A1 - Method of manufacturing components - Google Patents

Method of manufacturing components Download PDF

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Publication number
US20110259541A1
US20110259541A1 US13/141,443 US200913141443A US2011259541A1 US 20110259541 A1 US20110259541 A1 US 20110259541A1 US 200913141443 A US200913141443 A US 200913141443A US 2011259541 A1 US2011259541 A1 US 2011259541A1
Authority
US
United States
Prior art keywords
metallic material
manufacturing
component
cavity
metallic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/141,443
Other languages
English (en)
Inventor
Tymen Jacob Dinn Brom
Patrick Gerard Maher
Jonathan Clowes Pemberton
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Excalibur Steel Co Pty Ltd
Original Assignee
Excalibur Steel Co Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2008906602A external-priority patent/AU2008906602A0/en
Application filed by Excalibur Steel Co Pty Ltd filed Critical Excalibur Steel Co Pty Ltd
Assigned to EXCALIBUR STEEL COMPANY PTY LTD reassignment EXCALIBUR STEEL COMPANY PTY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BROM, TYMEN JACOB DINN, MAHER, PATRICK GERARD, PEMBERTON, JONATHAN CLOWES
Publication of US20110259541A1 publication Critical patent/US20110259541A1/en
Abandoned legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02F—DREDGING; SOIL-SHIFTING
    • E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
    • E02F9/28—Small metalwork for digging elements, e.g. teeth scraper bits
    • E02F9/2808—Teeth
    • E02F9/285—Teeth characterised by the material used
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/06—Casting in, on, or around objects which form part of the product for manufacturing or repairing tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/06—Melting-down metal, e.g. metal particles, in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/011—Layered products comprising a layer of metal all layers being exclusively metallic all layers being formed of iron alloys or steels
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
    • C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
    • C22C29/067—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds comprising a particular metallic binder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys

Definitions

  • the present invention relates to the formation of components having a shell formed from a first metallic material and an inner body formed from a second metallic material. It has particular application to the formation of wear resistant metallic components.
  • wear components are often mounted to earth moving buckets and similar machinery.
  • Typical wear components include wear bars, bucket heel shrouds and edge components.
  • the wear components are arranged to protect the parts of the machinery which would otherwise wear most rapidly.
  • the wear components are designed to be relatively easy to replace, when worn.
  • the conditions within the furnaces used in the above processes are tightly controlled to prevent oxidation of either the first or the second metal.
  • the furnace employed is a vacuum furnace, which is firstly evacuated of oxygen and may then be purged with an appropriate quantity of an inert gas such as nitrogen.
  • an inert gas such as nitrogen.
  • Such a furnace is expensive both to install and operate. Additionally, such furnaces frequently have adverse environmental impacts, with potential for noxious emissions. There are often limits to where vacuum furnaces can be sited.
  • the present invention seeks to provide a method for manufacturing components such as wear resistant components which provides some of the advantages of WO 02/13996 without requiring the evacuation and purging of a vacuum furnace.
  • the invention envisages a possible additional step of machining of the outside of the shell following cooling to remove any oxidation which occurs during the heating.
  • the invention is based on the understanding that the existence of a small quantity of oxygen in the interface between the first and second metallic materials may still allow for the formation of a sufficiently strong metallurgical bond.
  • the present invention proposes not to remove all oxygen from the environment in which the metals are being heated, but rather to restrict the flow of oxygen into the actual location of the bond. It is understood that this may result in oxidation occurring away from the bond location, but such oxidation is likely to be only to the surface of the component and hence can be machined away.
  • the method may include an additional step of maintaining the metallic materials above the liquidus temperature of the second metallic material for a sufficient period of time to allow at least partial fusion of the second material to the first material. It is expected that the materials will be held at this temperature sufficiently for substantially complete fusion to occur about the boundary between the first and second metallic materials. This time may be in the order of 15 minutes to 120 minutes.
  • the gas flow restricting means may be a cover sized and shaped to locate across the open end of the cavity.
  • the gas flow restricting means may be a container within which some or all of the second metallic material is located.
  • the steps of providing the second metallic material and of providing the gas flow restricting means may be achieved through providing the second metallic material in a container, the container having an opening complementary to the open end of the cavity, and then inverting the container and locating it above the cavity. Melting of the second metallic material will cause it to flow from the container into the cavity.
  • the present invention may be used in conjunction with the methods of co-pending PCT application PCT/AU2009/000816, the contents of which are incorporated herein by reference.
  • the second metallic material may be provided as alloy constituents, chosen so that during the process of the present invention the alloy constituents melt and mix to form a desired alloy composition, bonded to the outer shell.
  • the second metallic material may be an abrasion resistant metal, such as an abrasion resistant white cast iron. It is anticipated that white cast irons containing carbides of one or more of chromium, molybdenum, tungsten, niobium, vanadium and boron, or other suitable carbides, may be suitable for use in the method of the present invention.
  • the present invention will allow wear resistant components to be produced using relatively small and inexpensive kilns or furnaces, operating with a significantly smaller environmental impact than vacuum furnaces.
  • the types of kiln which may be suitable for the method include kilns generally used for the firing of pottery, provided they have a sufficiently high operating temperature.
  • the kiln may be heated by any convenient heat source, including conventional sources such as gas or electricity, or alternatively by sources such as oil or diesel fuel. Heating could also be provided by non-traditional means, such as induction heating or microwave heating.
  • FIG. 1 is a perspective of a wear resistant heel shroud formed using a method in accordance with the present invention
  • FIG. 2 is a perspective of an outer shell of the heel shroud of FIG. 1 , shown prior to the operation of the present invention
  • FIG. 3( a ) is a cross sectional schematic view of a container used in one embodiment of the present invention.
  • FIGS. 3( b ) and 3 ( c ) are sequential, cross sectional schematic views of the outer shell of FIG. 2 and the container of FIG. 3( b ) during formation of the heel shroud;
  • FIGS. 4( a ) and 4 ( b ) are cross sectional schematic views of the heel shroud of FIG. 1 during formation in accordance with a second embodiment of the present invention.
  • FIG. 1 shows a wear resistant mechanical component, being a heel shroud 10 .
  • the heel shroud 10 has an outer shell 12 , which may be formed from a high strength, weldable material such as a ferrous based material, or a nickel or titanium based alloy.
  • the heel shroud 10 has an inner body 14 , which is formed from an abrasion resistant material such as a chromium white iron. The following discussion refers to the method of manufacturing such an article.
  • FIG. 2 shows the outer shell 12 of the heel shroud 10 , before the formation of the inner body 14 .
  • the outer shell 10 defines a cavity 16 , having a base 18 and side walls 20 .
  • the cavity 16 has an opening 22 at an upper end thereof.
  • the opening 22 is substantially square.
  • FIG. 3( a ) shows a container 30 , formed of a heat resistant material such as a ceramic material.
  • the container 30 has an open top 32 .
  • the open top 32 is substantially complementary in shape to the opening 22 of the outer shell 12 , such that, when the container 30 is inverted, it can be placed about the opening 22 of the outer shell 12 to substantially seal the opening as shown in FIG. 3( b ).
  • the container 30 is filled with an abrasion-resistant material such as a chromium white iron 34 .
  • the container 30 is inverted and placed atop the outer shell 12 as shown in FIG. 3( b ).
  • the outer shell 12 and the container 30 are then heated in a furnace to a temperature above the solidus temperature of the chromium white iron 34 .
  • the chromium white iron flows from the container 30 into the cavity 16 .
  • the quantity of chromium white iron within the container 30 is chosen so as to fill the cavity 16 .
  • Furnace gases are precluded from entering into the cavity 16 due to a seal provided about the cavity opening 22 by the container 30 . Even where this is not a gas-tight seal, its effect is to greatly diminish the propensity for gas to flow into the cavity 16 .
  • the container 30 thereby acts as a gas flow restricting means.
  • the covered shell 12 containing white iron 34 is then heated above the liquidus temperature of the chromium white iron. At this point the white iron begins to fuse with the internal shell walls, thus giving rise to a metallurgical bond. This temperature is maintained for a predetermined time, which may be between 15 minutes and 120 minutes, depending on the particular metals used and the temperature to which the shell 12 is heated.
  • the entire arrangement can be cooled, to solidify the white iron 34 as the inner body 14 of the heel shroud 10 .
  • the heel shroud 10 may then be subjected to a machining operation.
  • FIGS. 4( a ) and 4 ( b ) show a different embodiment of the present invention, where constituent parts of the heel shroud inner body 14 are placed within the cavity 16 , which is then covered by a cover 40 .
  • the cover 40 acts to restrict the flow of gases into the cavity 16 .
  • the covered shell 12 may then be heated to a level where enough of the constituent ingredients melt so as to form the required alloy, as described in co-pending application number PCT/AU2009/000816.
US13/141,443 2008-12-23 2009-12-23 Method of manufacturing components Abandoned US20110259541A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AU2008906602 2008-12-23
AU2008906602A AU2008906602A0 (en) 2008-12-23 Method of manufacturing components
PCT/AU2009/001696 WO2010071940A1 (fr) 2008-12-23 2009-12-23 Procédé de fabrication de composants

Publications (1)

Publication Number Publication Date
US20110259541A1 true US20110259541A1 (en) 2011-10-27

Family

ID=42286801

Family Applications (1)

Application Number Title Priority Date Filing Date
US13/141,443 Abandoned US20110259541A1 (en) 2008-12-23 2009-12-23 Method of manufacturing components

Country Status (5)

Country Link
US (1) US20110259541A1 (fr)
AU (1) AU2009329829B2 (fr)
CA (1) CA2747878A1 (fr)
WO (1) WO2010071940A1 (fr)
ZA (1) ZA201105114B (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130160335A1 (en) * 2010-06-28 2013-06-27 Excalibur Steel Company Pty Ltd Wear resistant component
US20190368164A1 (en) * 2016-11-17 2019-12-05 Doosan Infracore Co., Ltd. Construction machine bucket part and manufacturing method therefor

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
UA114099C2 (xx) * 2012-01-31 2017-04-25 Зносостійкий матеріал і система та спосіб створення зносостійкого матеріалу

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1734313A (en) * 1928-05-26 1929-11-05 Malmborg Nils W Daniel Von Casting apparatus
US2315876A (en) * 1941-12-19 1943-04-06 Baker & Co Inc Casting of metal alloys
US4823513A (en) * 1987-10-13 1989-04-25 Mermark, Inc. Apparatus and process for vibratory finishing of parts
US4966222A (en) * 1989-10-05 1990-10-30 Paton Boris E Method of and apparatus for producing shaped castings
WO2002013996A1 (fr) * 2000-08-10 2002-02-21 Paul Graeme Huggett Procede servant a fabriquer des composites metalliques et composites fabriques au moyen de ce procede
US20080128176A1 (en) * 2005-11-10 2008-06-05 Heeman Choe Silicon carbide composite materials, earth-boring tools comprising such materials, and methods for forming the same

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4017480A (en) * 1974-08-20 1977-04-12 Permanence Corporation High density composite structure of hard metallic material in a matrix
US4052802A (en) * 1976-02-23 1977-10-11 Caterpillar Tractor Co. Ground-engaging tool with wear-resistant insert
US4933240A (en) * 1985-12-27 1990-06-12 Barber Jr William R Wear-resistant carbide surfaces
JPS645701A (en) * 1987-06-29 1989-01-10 Kubota Ltd Center for supporting rotor
US6652814B1 (en) * 2000-08-11 2003-11-25 Lifescan, Inc. Strip holder for use in a test strip meter

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1734313A (en) * 1928-05-26 1929-11-05 Malmborg Nils W Daniel Von Casting apparatus
US2315876A (en) * 1941-12-19 1943-04-06 Baker & Co Inc Casting of metal alloys
US4823513A (en) * 1987-10-13 1989-04-25 Mermark, Inc. Apparatus and process for vibratory finishing of parts
US4966222A (en) * 1989-10-05 1990-10-30 Paton Boris E Method of and apparatus for producing shaped castings
WO2002013996A1 (fr) * 2000-08-10 2002-02-21 Paul Graeme Huggett Procede servant a fabriquer des composites metalliques et composites fabriques au moyen de ce procede
US20080128176A1 (en) * 2005-11-10 2008-06-05 Heeman Choe Silicon carbide composite materials, earth-boring tools comprising such materials, and methods for forming the same

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130160335A1 (en) * 2010-06-28 2013-06-27 Excalibur Steel Company Pty Ltd Wear resistant component
US9027266B2 (en) * 2010-06-28 2015-05-12 Excalibur Steel Company Pty Ltd Wear resistant component
US20190368164A1 (en) * 2016-11-17 2019-12-05 Doosan Infracore Co., Ltd. Construction machine bucket part and manufacturing method therefor
US11814819B2 (en) * 2016-11-17 2023-11-14 Doosan Infracore Co., Ltd Construction machine bucket part and manufacturing method therefor

Also Published As

Publication number Publication date
ZA201105114B (en) 2012-11-28
AU2009329829A1 (en) 2011-07-28
AU2009329829B2 (en) 2016-06-02
WO2010071940A1 (fr) 2010-07-01
CA2747878A1 (fr) 2010-07-01

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Legal Events

Date Code Title Description
AS Assignment

Owner name: EXCALIBUR STEEL COMPANY PTY LTD, AUSTRALIA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BROM, TYMEN JACOB DINN;MAHER, PATRICK GERARD;PEMBERTON, JONATHAN CLOWES;SIGNING DATES FROM 20110627 TO 20110629;REEL/FRAME:026553/0152

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION