Caterpillar Inc.

M Brad Beardsley

Gary L Biltgen

Mark Steven Diekevers

Bao Feng

Kenneth W Burris

Xiangyang Jiang

Leonid Chuzhoy

Daniel Herbert Gerke

D Trent Weaver

Chuong Q Dam

Daniel Cavanaugh

Daniel Joseph Sordelet

Robert E Sharp

Karen Renee Raab

Kent A Koshkarian

John A Grassi

Justin Curtis Embrey

Mike D Bridges

Eric Kelsey

Kristin Ann Schipull

Robert Eugene Sharp

A bearing system includes a sleeve bearing supported on a shaft and a gear supported on the sleeve bearing. The shaft has an outer diameter shaft surface, the sleeve bearing has an inner diameter bearing surface and an outer diameter bearing surface, and the gear has a gear bore surface. At least one of the outer diameter shaft surface, the inner diameter bearing surface, the outer diameter bearing surface, and the gear bore surface includes an isotropic surface finish and a hard thin film over the isotropic surface finish. During a break-in period of operation of the bearing system, the hard thin film over the isotropic surface finish breaks in a counter surface of the bearing system to extend a hydrodynamic lubrication period of operation of the bearing system.

Machine bearing system including hard thin film and method of using same

A method and system for processing a bearing component to extend its useful life include using the component in the bearing assembly for a portion of its initial useful life and then removing the component from the bearing assembly. The surface of the removed component is subjected to isotropic finishing, after which a protective wear coating is applied to the surface of the component. Once processed, the used bearing component is reinstalled for use.

Remanufacturing of bearings using isotropic finishing and thin film coatings

A remanufactured planet carrier is disclosed having a first plate and a second plate spaced apart from and oriented generally parallel to the first plate. Supports join and support the first and second plates. The remanufactured planet carrier further has a plurality of first pin bores in the first plate and a plurality of second pin bores in the second plate. The first pin bores are parallel and generally aligned with the second pin bores. A cylindrical member extends from a central axis of the second plate away from the first plate with a shaft bore formed within the cylindrical member. The first and second pin bores and the shaft bore each have a surface layer with a hardness of at least about 180 BHN and a strength of at least about 500 MPa.

Planet carrier salvage process

A power rail includes an aluminum body and a wear coating including stainless steel. The power rail may also include a break-in coating having a lower hardness than the wear coating.

Coated power rail

A method of forming a composite overlay compound on a substrate includes forming a mixture including at least one component from a first group of component materials including titanium, chrome, tungsten, vanadium, niobium, and molybdenum. The mixture also includes at least one component from a second group of component materials including carbon and boron, and the mixture further includes at least one component from a third group of component materials including silicon, nickel, and manganese. The mixture of selected component materials is then applied to a substrate material to form an overlay compound on the substrate material. The overlay compound is fused to the substrate to form a metallurgical bond between the substrate material and the overlay compound.

Composite overlay compound

A component subjected to one or more of rolling, sliding, abrasion and bending contacts is disclosed. The component has a surface and functionally graded material (FGM) thermally sprayed on the surface to form an FGM coating. The FGM coating has a thickness and a plurality of material compositions. The FGM coating also has a plurality of elastic modulus profiles. Each elastic modulus profile consists of a plurality of elastic modulii at a plurality of corresponding points within that thickness. The elastic modulii are in the range from about 28 Mpsi to about 60 Mpsi. Optionally, there is also a plurality of carbon content profiles.

Component having a functionally graded material coating for improved

A method for applying a functionally gradient coating on a component, having a surface and subjected to one or more of rolling, sliding, abrasion and bending contacts, including the step of thermally spraying a functionally gradient material (FGM) on said surface that forms an FGM coating, said FGM coating having a thickness, a plurality of material compositions and a plurality of elastic modulus profiles. Each elastic modulus profile consists of a plurality of elastic modulii at a plurality of corresponding points within that thickness. The elastic modulii are in the range from about 28 Mpsi to about 60 Mpsi. Optionally, there is also a plurality of carbon content profiles.

Process for applying a functional gradient material coating to a

A carbon coated metal powder depositable by thermal spray techniques to form a metal coating is disclosed. The carbon coated metal powder has a composition comprising a metal powder and carbon adhered to the metal powder. The metal powder is coated with carbon to form a carbon coated metal powder. The carbon coated metal powder, after being thermally sprayed on to a substrate and after being formed into a metal coating on the substrate, has an oxygen content at least 20% by weight less than the oxygen content in the carbon coated metal powder prior to being thermally sprayed.

Carbon coated metal powder depositable by thermal spray techniques

A self-lubricating and wear resistant valve/valve guide combination for an engine includes a self-lubricating coating deposited on one of (a) the inner surface of the valve guide, or (b) the outer surface of the valve stem. A wear-resistant coating deposited on one of (a) the outer surface of the valve stem when the self-lubricating coating is deposited on the inner surface of the valve guide, or (b) the inner surface of the valve guide when the self-lubricating coating is deposited on the outer surface of the valve stem. The self-lubricating coating has a composition, by weight, consisting essentially of, (a) a first component, comprising, a metal-bonded chromium carbide in the range of about 60% to about 80%, (b) a second component, comprising, a soft noble metal in the range of about 1% to about 20%, and (c) a third component, comprising, a metal fluoride eutectic in the range of about 5 to about 20%. The wear-resistant coating has a composition, by weight, consisting essentially of, (a) chromium in the range of about 20% to about 30%, (b) nickel in the range of about 5% to about 15%, (c) tungsten in the range of about 1% to about 10%, and (d) cobalt in the range of about 50% to about 74%.

Self-lubricating and wear resistant valve/valve guide combination for

A process for reducing oxygen content in thermally sprayed metal coatings comprises the following steps. A metal powder is provided. The metal powder has a particle size in the range of from about 10 .mu.m to about 500 .mu.m. Carbon is adhered and coated to the metal powder to form a carbon coated metal powder. The carbon is present in the range of from about 0.1% to about 2.0% by weight of the carbon coated metal powder. The carbon coated metal powder is thermally sprayed onto a substrate and a metal coating is deposited on the substrate. The metal coating has a lower oxygen content compared to the oxygen content of the carbon coated metal powder.

Process for reducing oxygen content in thermally sprayed metal coatings

A method for reducing oxygen content in metal coatings deposited by gas stabilized plasma spray techniques comprises the following steps. A metal powder is provided. Carbon is adhered and coated to the metal powder and a carbon coated metal powder is formed. A primary gas is provided to a plasma spray gun at a flow rate in the range of about 30-80 liter/min. A carrier gas is also provided to the plasma spray gun at a flow rate in the range of about 4-8 liter/min. The carbon coated metal powder is provided to the plasma gun at a flow rate in the range of about 30-85 gms/min. The plasma spray gun is positioned at a stand-off distance in the range of about 100-175 mm from a substrate. The plasma spray gun is energized with power in the range of about 28-42 kW. The carbon coated metal powder is sprayed onto the substrate and a metal coating having an oxygen content at least 20% by weight less than an oxygen content of the metal powder, is deposited.

A process for applying a uniformly adherent protective tantalum oxide coating on a portion of a ceramic glow plug for protecting the glow plug against the corrosive/erosive environment generated by the burning of alternative fuels in a diesel engine. The coating is tantalum oxide deposited on a silicon nitride glow plug by plasma spray deposition techniques.

Process for coating a ceramic glow plug portion with a corrosion

A flowable slurry comprising powder matrix particles and reinforcing particles is pumped, under pressure, through an atomizing nozzle to form discrete droplets containing reinforcing particles coated with the powder matrix particles The discrete droplets are suspended in an elevated temperature environment for a sufficient time to evaporate the water from the droplets and form nonreacted reinforced powder particles. The reinforced powder particles are nonagglomerated and are suitable for immediate use as powder for thermal spray coatings or for dry processed compacted structural components.

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Laura, IL, United States of America

M Brad Beardsley