China TZ Overlay Technology Extends Bearing Service Life

Pioneering the Technological Frontier: Defying Industry Limits!

Recently, our company has achieved a breakthrough by using lasers as "embroidery needles" and high-performance alloys as "threads" to precisely "stitch" a uniform cladding layer onto the surface of gray cast iron. This innovation significantly enhances the material's performance and improves bearing durability. The groundbreaking process fills a critical domestic technology gap, laying a solid foundation for expanding our product market. Currently, the technology is in the crucial debugging and testing phase.

The Laser Cladding Process

Traditional methods, such as the "casting process," involve pouring molten alloy directly onto gray cast iron. However, this often results in uneven coating thickness and poor adhesion under high temperatures, severely compromising bearing reliability and lifespan.

TZ has long been exploring laser cladding technology, but combining gray cast iron with dissimilar alloys has been a major industry challenge. The two materials differ drastically in melting points and crystalline structures—like an "incompatible pair"—leading to cracks and delamination during fusion.

To resolve this conflict, our welding research team adopted an innovative approach: by selecting compatible welding materials and precisely controlling laser energy density, they enabled the alloy to "gently fuse" with the gray cast iron, forming an ultra-thin yet tough "anti-friction armor." This unique coating ensures the base material withstands extreme pressure while maintaining smooth operation, achieving a perfect balance of strength and flexibility.

Breaking Through Barriers: From Setbacks to Success

"In the early stages, frequent porosity issues nearly halted progress," recalled a team member. "We spent entire afternoons staring into microscopes, determined to crack this challenge." Innovation is born from relentless effort—and that very night, microscopic analysis revealed the root cause: a mismatch between laser energy parameters and material melting points. After urgent adjustments, a new round of tests finally showed promise.

After hundreds of refinements and countless sleepless nights, the team conquered this "hard nut": latest tests confirm the cladding layer's bonding strength far exceeds expectations, with remarkable improvements in wear and corrosion resistance. Ongoing long-term stability tests will pave the way for industrial-scale application.

A New Era for Surface Modification

This breakthrough not only equips bearings with a high-performance "golden armor" but also opens new possibilities for gray cast iron surface enhancement. Stay tuned for this "cutting-edge tech" to shine beyond the lab and onto production lines!