Abstract: A work machine, such as a hauler at a mining site, includes a conductor rod housing concentric metal tubes for receiving electrical power from a contactor sliding on a power rail. Electrical connectivity between conductors within the conductor rod are provided using a conductive liquid. Corrosion barriers are used to protect the conductors while maintaining the electrical connectivity between the conductors.

Abstract: An example hydraulic system component of a machine includes a protective coating deposited by high velocity air fuel (HVAF) thermal spray, exhibiting high adhesion strengths and surface morphologies that promote lubricant adhesion and reduce the leakage of oil and/or hydraulic fluid from the hydraulic system. The coating may have surface roughness with RZ values less than 2 ?m and hardness of 1000 Vickers or greater. The HVAF coating may be thinner than conventional coatings with thicknesses less than 100 ?m. The HVAF coating may be deposited on a variety of steel components with adhesion strengths greater than those achieved by high velocity oxygen fuel (HVOF). The HVAF coating may be formed without time consuming roughening and/or post-grind operations, resulting in cost savings compared to conventional coatings. The coatings may have operational lifetimes of 1000 hours or more.

Abstract: An example hydraulic system component of a machine includes a protective coating deposited by high velocity air fuel (HVAF) thermal spray, exhibiting high adhesion strengths and surface morphologies that promote lubricant adhesion and reduce the leakage of oil and/or hydraulic fluid from the hydraulic system. The coating may have surface roughness with Rz values less than 2 ?m and hardness of 1000 Vickers or greater. The HVAF coating may be thinner than conventional coatings with thicknesses less than 100 ?m. The HVAF coating may be deposited on a variety of steel components with adhesion strengths greater than those achieved by high velocity oxygen fuel (HVOF). The HVAF coating may be formed without time consuming roughening and/or post-grind operations, resulting in cost savings compared to conventional coatings. The coatings may have operational lifetimes of 1000 hours or more.

Abstract: A steel track chain component, such as a track bushing, may be formed with a carburized portion, a hardface portion, and a core portion. The core portion may be softer than the carburized portion, which in turn, may be softer than the hardface portion. This configuration of the various portions of the component may allow for relatively high wear resistance of the component, as well as toughness. The core portion may be mostly ferrite crystal structure, while the carburized portion and the hardface portions may include martensitic and/or austenitic crystal structure. The carburized portion may be formed by carburizing the track chain component in a heated and carbon rich environment. The hardface portion may be formed by welding a hardface alloy over at least a portion of the carburized portion.

Abstract: A steel track chain component, such as a track bushing, may be formed with a carburized portion, a hardface portion, and a core portion. The core portion may be softer than the carburized portion, which in turn, may be softer than the hardface portion. This configuration of the various portions of the component may allow for relatively high wear resistance of the component, as well as toughness. The core portion may be mostly ferrite crystal structure, while the carburized portion and the hardface portions may include martensitic and/or austenitic crystal structure. The carburized portion may be formed by carburizing the track chain component in a heated and carbon rich environment. The hardface portion may be formed by welding a hardface alloy over at least a portion of the carburized portion.

Abstract: A method for installing a sensor on a component is provided. The method includes attaching the sensor to a surface of the component. The method includes covering the sensor using a metal wire. The method includes applying a multilayer coating on the metal wire. Applying the multilayer coating includes applying a first coating. The first coating is capable of being machined. Applying the multilayer coating includes machining the first coating and applying a second coating over the first coating. The second coating is a ceramic oxide and the second coating is configured to serve as a thermal and dielectric barrier. Applying the multilayer coating also includes applying a third coating over the second coating. The third coating is configured to provide erosion resistance.

Abstract: A method for installing a sensor on a component is provided. The method includes attaching the sensor to a surface of the component. The method includes covering the sensor using a metal wire. The method includes applying a multilayer coating on the metal wire. Applying the multilayer coating includes applying a first coating. The first coating is capable of being machined. Applying the multilayer coating includes machining the first coating and applying a second coating over the first coating. The second coating is a ceramic oxide and the second coating is configured to serve as a thermal and dielectric barrier. Applying the multilayer coating also includes applying a third coating over the second coating. The third coating is configured to provide erosion resistance.

Abstract: A method for coating a component, the method including the steps of depositing, by a thermal spraying process, simultaneously a first material and a second material on a surface of the component to form a rough coating, wherein the first material is of higher hardness than the second material and removing a layer of the rough coating such that the second material plastically deforms and produces a finished coating having a finished surface with an Rz value of less than 2 ?m.

Abstract: The present disclosure is related to a cladding composition. The cladding composition may include cladding powder particles and flux particles. The flux particles may have an average particle size of less than about 40 ?m, and more than about 50% of the flux particles may adhere to the surfaces of the cladding powder particles.

Abstract: A fabrication method is provided for use in making a component. The fabrication method may include generating a laser beam at a first orientation relative to a wear surface of the component to produce a first laser beam spot having a first characteristic, and feeding a cladding material into the first laser beam spot to produce a cladding layer on the wear surface. The fabrication method may also include generating a laser beam at a second orientation relative to the wear surface of the component to produce a second laser beam spot having a second characteristic, and moving the second laser beam spot along the cladding layer to substantially flatten the cladding layer.

Abstract: A fabrication method is provided for use in making a component. The fabrication method may include generating a laser beam at a first orientation relative to a wear surface of the component to produce a first laser beam spot having a first characteristic, and feeding a cladding material into the first laser beam spot to produce a cladding layer on the wear surface. The fabrication method may also include generating a laser beam at a second orientation relative to the wear surface of the component to produce a second laser beam spot having a second characteristic, and moving the second laser beam spot along the cladding layer to substantially flatten the cladding layer.

Abstract: The present disclosure is related to a cladding composition. The cladding composition may include cladding powder particles and flux particles. The flux particles may have an average particle size of less than about 40 ?m, and more than about 50% of the flux particles may adhere to the surfaces of the cladding powder particles.

Abstract: A used component, such as an engine block or engine head, has at least one dimension that does not match a dimensional specification for the component. A thermal spray coating of FeAlSiC is applied to build up the dimension. The excess coating is milled off so that the body and coating have a second shape that matches the dimensional specification for the component. The coating has an ordered DO3 crystal structure with a stable aluminum oxide scale that produces oxidation resistance at about 700° C.