Presentation on theme: "XADO – TECHNOLOGY modifies friction surfaces. This is a brand-new, environmentally friendly, energy saving technology for the equipment maintenance and."— Presentation transcript:
XADO – TECHNOLOGY modifies friction surfaces. This is a brand-new, environmentally friendly, energy saving technology for the equipment maintenance and repair Scientific research Institute Chin Huan University Staff member Lyu Dzja Sjun
In the whole world no less than 1/3 of all produced energy is wasted to reduce friction. About 2% of the national economy GDP is lost because of friction.
Ways to reduce friction losses: Creation of new wear-resistant materials Changing of operating conditions of the friction surfaces by using special additives to lubricants Using new types of top quality lubricants
XADO – technology has triple effect: lubricating, restoring and surface modification. Today this technology is the most effective way to reduce friction. Very efficient way to save energy and resources. The most simple and economical way to harden the surface.
Forming process and characteristics of the metalloceramics layer
12V- 90 diesel engine of the drilling rig worked in Sheng Li oilfield. Having been treated by XADO revitalizant it operated 2000 hours in excess of planned rate.
This water pump gear shift of a locomotive was treated by XADO and it ran km extra.
Test period hours after XADO revitalizant application XADO laboratory test Circular lubricating, oil. Lubrication intensity - 3 drops per second Laboratory friction machine
Test conditions: Rotation speed – 800 rpm; Load on the roller increased after a certain period of time: operating hours – load 10 kg; operating hours – load 15 kg; operating hours – load 25 kg.
Surface hardness increased significantly and reached the level of the diamond-like material
Table of disc surface hardness on the wear traces Friction machine 1- before test 2- after test
Tables and diagrams of nanohardness of wear traces on the disc surface at a depth of 50 nm and 20 nm After 300 hours of tests on the friction machine
Table of measurements and a diagram of nanohardness of the roller friction surface at a depth of 50 nm after tests on the friction machine 300 hours of roller operation during test period
Table of measurements and a diagram of nanohardness of the 12V- 90 diesel engine cylinder (Sheng Li Oilfield) at a depth of 50 nm Operating time of the engine in excess of the planned rate hours
Average nanohardness values: 1 – disc at a depth of 50 nm; 2 – disc at a depth of 20 nm; 3 – roller; 4 – gear wheel of the water pump; 5 – cylinder of 12V- 90 diesel engine.
Roughness of the working surfaces treated by XADO decreases reaching the smoothness level of the mirror surface
Results of Noncontact measurements of the surface nanoroughness in the 12V- 90 engine cylinder. Three-dimensional device for nanoroughness measurement
Table of nanoroughness measurements in three points of the working surface of 12V- 90 engine cylinder Measurement number Ra, nm Rq, nm Rz, nm Rt, nm Average value
XADO metalloceramics layer is a thin colorless coating. Its thickness can vary from 10 nm to several microns depending on the conditions of friction. The general structure of the coating is similar to that of the diamond-like material.
Chemical analysis of the cross section of the friction machine disc. The analysis was made with the device in a non-contact way by linear displacement of the probe. Red graph – content of carbon at different depth. Green graph – content of iron at different depth.
Photo on the left – cross section of the friction machine roller (sample with black protecting rubber). On the right – table and diagram of the elements content in the surface layer. 3.8%C5.5%C 11.32%C
Photos of the sample with different enlargement, cross section of 12V- 90 diesel engine cylinder surface, drilling rig. А – cylinder material; В – XADO surface layer; С – special protecting rubber which is necessary in order to prepare the sample for the analysis.
Analysis of the 12V- 90 diesel engine cylinder surface. Percentage of chemical elements in the test points: А – at a depth of 6 micron В – on the cylinder surface (XADO metalloceramics layer) С – protective rubber (special sample for analysis) 7.09%C7.95%C
«RAMAN» device. Friction machine disc. Each graph on the upper diagram – measurements in two points. On the lower diagram – measurement in the spot of the burr (red graph), black graph – measurement results for graphite. Visible spectrum of the disc surface wear
«Raman» device Friction machine roller Results of the measurements in the second point (cavity in form of a scratch)
«Raman» device Friction machine roller - result of the measurements in the third point (cavity in form of a pit)
« Raman » device Friction machine roller. Result of the measurements in the forth point (separate area).
Laboratory analysis of the diamond-like layer «Raman» device On the left – optical spectrum of the friction machine roller. On the right – summary diagram of: - smooth roller surface (black graph 1); - scratches on the roller surface (red graph 2); - deepenings on the roller surface (green graph 3); - separate area on the roller surface (blue graph 4).
Laboratory analysis of the diamond-like layer. «Raman» device - red graph – XADO coating on the surface of 12V- 90 diesel engine cylinder; - black graph – graphite analysis.
Results of analysis of the friction machine roller photoelectron spectrum ( XPS – analysis ) Chart of the photoelectron spectrum elements. XPS - analysis
Table of the chemical elements percentage in the surface layer. XPS - analysis
12V- 90 diesel engine cylinder Measurement of the elements percentage at a depth of the surface coating Surface of the 12V- 90 diesel engine cylinder
Friction coefficient decreased significantly (less than 0.01 )
Results of the friction coefficient measurements before XADO treatment after XADO treatment
Friction machine Wear comes to «0», moreover the working surface is restored
Diagram of the wear on the friction machine (roller-disc). ( black graph – oil without XADO, red – oil containing XADO ).
Friction machine. Wear-out percent of the roller (0-16 hours of operation on oil without XADO; hours of operation – oil containing XADO). % - wear, h – hours of operating;
Practical examples of wear restoration using XADO-technology
From December 2002 to August 2004 tests of the diesel locomotives, DF8B model (№5317; №5319), were carried out on the territory of the “ХАНИ” railway. After using XADO the locomotive ran extra km and a mid-life repair was made. It ran km till May 2005 and a mid-life repair was made again.
Measurements results of the deviations of crankshaft journals diameter of the DF 8B locomotive engine after treatment and km run Main journals of the crankshaft 230 мм №1 №3 №5 №7 №9 (initial) (mid-life repair) Rod journals of the crankshaft 210 мм №1 №3 №5 №7 (initial) (mid-life repair)
Measurements of crankshaft journals of the DF 8B locomotive engine after treatment and km run Wear of the main journals of the crankshaft 230 mm, mm №1 №3 №5 №7 № Wear of the Rod journals of the crankshaft 210 mm, mm №1 №3 №5 №
Sheng Yang province, China Aircraft engines producing plant «Rassvet». Coordinate boring machine, vertical-type machine, produced in France. Results of the spindle vibration level measurements after XADO treatment Date of the measurement Spindle vibration, vertical(mm) Spindle vibration, horizontal (mm) Spindle revolutions (rpm) Time of operation after XADO treatment (hours)
XADO products in comparison with regular oils have a fundamental difference in working surface modification
Molecular structure of different oil additives Surface-active substances Chemically active substances Anti-burr additives
Boundary friction of the surface Boundary friction Liquid friction
Examples of operation without oil after XADO treatment in presence of notaries 1. February 10, Sya Li taxi with 3-cylinder engine, city of Tyan Din. 660 km run, no breaking 2. April 14, Audi А6 and Foukan, ran 326 km in mountains and on the highway without oil ( out of which 160 km off the road in mountains), no breaking 3. June 18, Volkswagen Jetta, ran without oil 108 km of the Pekin 5 th ring, no breaking
Traditional greases do not have restoring properties In recent years the researchers added to the grease solid grains of such chemical elements as: Cu, Ag,TiO 2, SiO 2, as well as diamonds. In this case forming of the continuous layer on the friction surfaces did not occur.
Layer on the friction surface after adding hard grains to the grease
XADO technology has perfect restoring properties. Its secret consists in the ability of XADO particles to capture iron particles and to bring them back to wear surface, forming a new modified layer.
Forming of XADO layer on the friction surface
Results of ferrographic analysis of laboratory oil sample in the friction machine XADO compound is added to oil. Wear intensity, it is defined according to iron content in oil.
Photos of oil samples in the friction machine containing iron particles
Bewick State registration number № H68675 After the first 450 km run the sample of oil was taken for analysis of iron content and XADO revitalizant for gasoline engines was added. Then the samples were taken after 600 km;1600 km, 3600 km and 6600 km run. Below you can see the photos of corresponding samples: H , H ,H ,H ; H Oil volume of each sample – 1 ml.
Relation between intensity of H68675 engine wear and the distance run
Photos of H68675 engine oil samples
Scan of the surface of 12V-90 engine cylinder with XADO layer
Stages of restoring with XADO compounds 1. Superfitting 2. Energy activity of XADO particles 3. Adhesion of particles to the friction surface 4. Diffusion of XADO particles to the surface layer 5. Filling-in of micro roughnesses and formation of the metalloceramics layer
Scheme of formation of XADO coating on friction surfaces
XADO metalloceramics layer
Main research tasks: 1.To define the principles of XADO technology operation and to determine the test methods. 2.To extend the area of application, constantly improve the technology application methods. 3.To investigate new area of application in order to extend capabilities of traditional treatment of equipment. 4. To analyze and develop constantly XADO technology.