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METHOD AND SYSTEM FOR CAST IRON COMPONENT REPAIR

IP.com Disclosure Number: IPCOM000241601D
Publication Date: 2015-May-15
Document File: 5 page(s) / 126K

Publishing Venue

The IP.com Prior Art Database

Abstract

A method and system of repairing a cast iron component is disclosed. The system is a Powder Micro Spark Deposition (PMSD) system which includes a spindle connected to a power supply and a powder feeding system. The spindle is connected with a roller electrode that produces short-duration electrical pulses to deposit a powder material to a metallic substrate. The powder feeding system includes powder feeding channels through which a powder repair material is deposited on the cast iron component.

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METHOD AND SYSTEM FOR CAST IRON COMPONENT REPAIR

BACKGROUND

The present disclosure relates generally to a welding process and more particularly to a Powder Micro-Spark Deposition (PMSD) system with a roller electrode for welding a cast iron component.

Generally, cast iron compositions have high carbon content. Due to high carbon content, cast iron has low tensile strength as compared to other forms of refined iron. Also, it is difficult to weld repair components fabricated using cast iron due to high carbon content. Conventional welding processes of cast iron require high heat input which results in crack formation and deposition of a white iron layer on the cast iron. Other techniques such as thermal spray and electroplating cannot form metallurgical bonding in cast iron to weld it efficiently.

A conventional technique employs a Powder Micro-Spark Deposition (PMSD) system for metallurgical bonding. PMSD is a cold welding process that deposits powder material to a metallic substrate in short-duration electrical pulses. PMSD is an automatic process that requires low heat input and can be utilized for minimal heat affected zone (HAZ). However, the PMSD system lacks wide bead deposition to cover welding of a large area. Figure 1 depicts a PMSD system.

Figure 1

Another conventional technique includes a hybrid repair and coating process via PMSD system. The hybrid process includes restoration and coating with silver to improve lifetime of the repaired region. Yet another conventional technique includes one of a laser, electron beam (EB) or PMSD method to seal a repair region with metal inserts and form a solid bonding by hipping. A cold spray may also be used to repair forged components. However, the above described conventional techniques are not consistently effective in welding components fabricated using cast iron.

 

It would be desirable to have a technique for efficient welding of cast iron components.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 depicts a Powder Micro-Spark Deposition (PMSD) system with a roller electrode.

Figure 2 depicts a spindle and the roller electrode coupled with the spindle.

Figure 3 depicts powder material deposition on a cast iron component.

Figure 4 depicts a dense and crack free microstructure formed by depositing a nickel based alloy using the PMSD system.

Figure 5 depicts a welded cast iron component with no signs of peeling or flaking of the deposit.

DETAILED DESCRIPTION

A method and system of repairing a cast iron component is disclosed. The system is a Powder Micro Spark Deposition (PMSD) system which includes a spindle connected to a power supply and a powder feeding system. The spindle is connected with a roller electrode that produces short-duration electrical pulses to deposit a powder material on a metallic substrate. The roller electrode is specifically used fo...