Fraunhofer-GesellschaftBronze alloy plain bearings can withstand extreme loads, such as those experienced in aircraft engines, wind turbines, and high-performance motors. However, manufacturing them is comparatively inefficient. Conventional casting processes take around three days and result in more than 90 percent material loss. Additionally, lead-containing bronze alloys are often used, which do not comply with current EU directives.
In the "CoilCladding" research project, the Fraunhofer IPT uses Express Wire Coil Cladding (EW2C). This additive technology, developed and patented by the Fraunhofer IPT, provides a resource- and cost-efficient way to coat rotationally symmetrical components.
First, a bronze wire is formed into a spring. It is placed on the shaft to be coated and welded on with a high-power laser. During this process, the shaft rotates around its own axis. Because the wire feed and welding processes are decoupled, application rates of up to 14 kg of wire per hour can be achieved. This is significantly higher than with any other wire-based additive process. The result is greatly reduced production times, minimal material loss, and a completely lead-free coating.
The EW2C process has applications far beyond the bearing industry and can be used wherever demanding coatings are applied to rotating components.
Here is a website about the project.
Contact:
Fraunhofer-Institut für Produktionstechnologie IPT
Stefan Gräfe M.Eng.
Steinbachstr. 17, 52074 Aachen
Telefon +49 241 8904-254
Mail: stefan.graefe@ipt.fraunhofer.de
