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Spur gear teeth reconstruction via direct laser deposition

Rekonstruktion der Stirnradverzahnung mittels direkter Laserauftragung

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Abstract

Fatigue damage, such as pitting and tooth root fatigue fracture, is one of several gear failure modes encountered in practical applications. Some of these failure modes are traditionally repairable, while others are known to be catastrophic and unrepairable. Direct Laser Deposition (DLD) is a Metal Additive Manufacturing process that could overcome this problem and extend the useful gear life. The DLD repair process proved to be applicable in several cases. Nevertheless, concrete applications for gears are still scarce and limited to preset teeth reconstruction without discussing functional applications. Based on that perspective, this research aims to evaluate the DLD performance of a gear under actual operation. This work details the strategy applied to restore a base material case-hardened 16 MnCr 5 FZG‑C Type C-GF pinion using a DLD combination of pure Inconel 625 (MetcoClad 625) for the tooth core and pure AISI 431 (Metco 42C) as a superficial coating. The pinion was tested for over 2.7 million cycles under different load stages (K1 to K9), functionally resisting until a static torque of 215.6 Nm, although it presented severe surface damage development throughout the campaign. This exploratory work thoroughly discusses the drawbacks encountered in the repair process, materials characterization, surface evolution of the restored teeth against base material, and mass loss during the tests.

Zusammenfassung

Ermüdungsschäden, wie z. B. Graufleckigkeit und Zahnfußermüdungsbruch, sind eine von mehreren Getriebeausfallarten, die in praktischen Anwendungen auftreten. Einige dieser Ausfallarten sind traditionell reparierbar, während andere als katastrophal und nicht reparierbar bekannt sind. Die Reparatur durch direkte Laserabscheidung (DLD) ist ein additives Fertigungsverfahren, das diese Probleme überwinden und die Lebensdauer des Getriebes verlängern könnte. Das DLD-Reparaturverfahren hat sich in mehreren Fällen als anwendbar erwiesen, von Schienen bis zu Zahnrädern. Dennoch sind konkrete Anwendungen für Zahnräder noch rar und beschränken sich auf die Rekonstruktion von Zähnen, ohne funktionelle Anwendungen zu diskutieren. Basierend auf dieser Perspektive zielt diese Forschungsarbeit darauf ab, die DLD-Reparaturleistung eines FZG-Getriebes unter realem Betrieb zu bewerten. Diese Arbeit beschreibt die Strategie zur Wiederherstellung eines einsatzgehärteten 16 MnCr 5 FZG-Typ-C-Ritzels aus Grundmaterial unter Verwendung einer DLD-Kombination aus reinem Inconel 625 (MetcoClad 625) für den Zahnkern und reinem AISI 431 (Metco 42C) als Oberflächenbeschichtung. Das Ritzel wurde über 2,7 Mio Zyklen in verschiedenen Belastungsstufen (K1 bis K9) getestet und hielt bis zu einem Drehmoment von 215,6 Nm funktionell stand, obwohl es während der gesamten Versuche Oberflächenschäden aufwies. Diese explorative Arbeit diskutiert gründlich die Nachteile, die beim Reparaturprozess, der Materialcharakterisierung, der Oberflächenentwicklung der reparierten Zähne gegenüber dem Basismaterial und dem Masseverlust während der Tests aufgetreten sind.

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Acknowledgements

The authors gratefully acknowledge the financial support of several projects and grants, namely:

National Funds through Fundação para a Ciência e a Tecnologia (FCT) under the PhD grant 2021.05562.BD;

GEAR3D under project POCI-01-0247-FEDER-039848;

LAETA under project UID/50022/2020

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Authors and Affiliations

  1. FEUP, Porto, Portugal

    P. C. Romio, J. H. O. Seabra, C. M. C. G. Fernandes & M. F. Vieira

  2. INEGI, Porto, Portugal

    P. C. Romio, P. M. T. Marques, J. H. O. Seabra, C. M. C. G. Fernandes, J. Gil, R. Cardoso & M. F. Vieira

  3. SERMEC Group, Porto, Portugal

    J. M. Cruz

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Correspondence to P. C. Romio.

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P.C. Romio, P.M.T. Marques, J.H.O. Seabra, C.M.C.G. Fernandes, J. Gil, R. Cardoso, M.F. Vieira and J.M. Cruz declare that they have no competing interests.

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Romio, P.C., Marques, P.M.T., Seabra, J.H.O. et al. Spur gear teeth reconstruction via direct laser deposition. Forsch Ingenieurwes 88, 1 (2024). https://doi.org/10.1007/s10010-023-00721-3

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