Job Recruitment Website - Job information - Metal self-repair

Metal self-repair

Automatic repair technology of metal wear is a revolutionary new technology in the field of surface engineering. The application of this technology can not only prevent the wear of machine parts, but also repair the worn surface of the machine in long-term operation, thus greatly prolonging the service life of the equipment and reducing energy consumption, which is impossible for various oil additives sold in the market. This technology can be applied to any part of mechanical equipment where friction occurs.

I. Technical characteristics

ART adopts the invention patent "a mineral powder lubricating composition" (the particle size is not more than 10μm) and adds it to oil and grease for use. Does not react chemically with oil products, does not change the viscosity and properties of oil products, has no toxic and side effects in use, and is harmless to the environment and human body. Wear-resistant protective layer can be formed on the friction surface of mechanical pARTs treated by art, so as to:

1. Change the lattice structure of friction surface and surface layer of mechanical parts to make them more uniform and energy stable.

2. Significantly improve the physical, chemical and mechanical properties of contact and friction surfaces.

3. Selectively compensate the worn surface to optimize the clearance of the friction pair.

4. Reduce the mechanical loss.

Ferrography of ultrafine powder particles (

I. Technical characteristics

1. Change the lattice structure of friction surface and surface layer of mechanical parts to make them more uniform and energy stable.

2. Significantly improve the physical, chemical and mechanical properties of contact and friction surfaces.

3. Selectively compensate the worn surface to optimize the clearance of the friction pair.

4. Reduce the mechanical loss.

Ferrography of ultrafine powder particles (

5. It forms a chemical bond with the original metal surface, has no obvious interface, and will not delaminate or fall off.

The main performance parameters of the protective layer are as follows:

Friction coefficient μ 0.003-0.007 (one order of magnitude lower than oil film lubrication)

The microhardness Hv 690-1 100 (3 times higher than the matrix1-).

Impact strength 50 kg/mm2

Linear expansion coefficient 13.6- 14.2 (same as steel)

The surface roughness belongs to the bright luster surface of aurora surface.

High temperature resistance 1575- 1600oC

Corrosion resistance, high humidity, marine environment, no corrosion in acid-base medium.

Optical microscope image of cermet protective layer of internal combustion engine cylinder liner

BX60 optical microscope image of FALEX sample

Second, the efficacy of art.

With the increase of the thickness of the protective layer, it can not only compensate the gap, but also repair the worn metal surfaces of various machines in situ without disassembly, so as to restore the original shape of the parts. It can also strengthen the pretreatment of the surface of new parts, so as to significantly reduce friction vibration, reduce noise, save energy, and finally realize the repair of the geometric shape of the friction surface of parts and the optimization of fitting clearance. Domestic practice in the past three years has proved that the main effects of this technology are:

1. Repair the worn parts in situ without disassembly, restore the original size, prolong the service life and reduce the maintenance cost.

The diesel locomotive of a diesel locomotive depot runs 6.5438+0.2 million kilometers. After adding repair materials, the cylinder liner and piston ring returned to the prototype size and remained zero wear after running for more than 400,000 kilometers. In the test of two DF 1 1 locomotives, the diesel locomotive was decomposed after running for 300,000 kilometers. The test report of the First Metrology and Testing Research Center of the National Metrology and Testing Unit of the Commission of Science, Technology and Industry for National Defense concluded: "... after running for 300,000 kilometers, the actual dimensions of the above-mentioned main friction pairs still meet the requirements of new products". Make sure that the piston, piston ring, cylinder liner, bearing and all friction parts of diesel engine are free of wear. Leaders and experts from the Equipment Department of the Transportation Bureau of the Ministry of Railways, Tsinghua University State Key Laboratory of Tribology and other related units agreed at the decomposition site that ART can not only change the original 300,000-kilometer repair system, but also greatly improve the online utilization rate of locomotives. The introduction of this technology will lead to a revolution in tribology. At the beginning of 2002, a railway bureau took the lead in popularizing and applying 100 locomotive in four sub-bureaus. As of July, 2003, all the test locomotives have entered the first intermediate repair course, and the first and ninth cylinders have been disassembled and inspected according to the requirements of the technical department, confirming that the piston, piston ring and cylinder liner of diesel engine meet the technical scope of intermediate repair, and continuing to carry out the second intermediate repair for 600,000 kilometers. Among them, 8 DF 1 1 locomotives have completed the 600,000-kilometer test in the second intermediate maintenance period.

2.ART fundamentally changed the traditional concept of friction. The ultra-low friction coefficient greatly reduced the friction power consumption, and the energy-saving effect was obvious. Taking the above-mentioned Beijing diesel locomotive as an example, after adding repair materials, the fuel saving rate reaches over 9%. In 2002, 65438+February 65438+September passed the appraisal of scientific and technological achievements organized by Beijing Science and Technology Commission. On June 2, 2003, the scientific and technological achievements organized by the Science and Technology Committee of Beijing Railway Bureau passed the evaluation. The evaluation committee thinks: "The popularization and application of this technology can promote the reform of diesel locomotive maintenance system, bring considerable economic benefits and have the value of further popularization and use."

3. Using this technology in power machinery has obvious environmental protection effect. Because the sealed working face is strengthened, the combustion dynamic characteristics are improved and the exhaust pollution is reduced.

The main performance indicators that can show the efficacy of antiretroviral therapy are as follows:

The compression pressure is increased to the standard value;

The idle oil pressure of hot engine increases1.0-1.5 kg/cm2;

Idle fuel consumption: save 5-25% or even more;

Energy consumption: reduce by 5-30% or more;

The output power is increased by 5-25% or more;

Reduce the emissions of harmful gases such as carbon monoxide and hydrocarbons by more than 10-50%.

4. Ultra-hard and ultra-smooth friction surface can make gasoline locomotives and diesel locomotives travel more than 200 kilometers without oil lubrication.

5. Using this technology on all kinds of bearings, the average bearing clearance is reduced by more than 0.02mm, the surface hardness is improved, the friction vibration and noise are obviously reduced, and the service life of bearings can be extended several times. The life test of the tensioner bearing of 6205-2RSIXI mini-car treated with "metal wear self-repairing material" was carried out by the National Center for Bearing Quality Supervision and Inspection. The normal test life of the bearing is L 10= 126h. When the test reaches 2 1 life, the raceway and roller surface of bearing ring are basically not worn.

6. Surface strengthening can improve the service life and characteristics of tools, cutters, molds and measuring tools, such as wear resistance and reliability.

Third, the engineering orientation of art.

ART has its unique action principle and material surface modification function. In fact, it is an original and brand-new surface strengthening and repairing technology, and art belongs to the category of surface engineering.

Surface strengthening and repairing technology is to use various surface engineering means to give the original or damaged surface a new physical and chemical state, improve the mechanical properties of the surface, and achieve the purpose of strengthening or repairing the friction surface.

ART is an innovative in-situ self-repair technology for metal wear.

Friction is a process of energy loss, while wear means waste of materials. In the process of design, operation and maintenance of mechanical equipment, if tribology knowledge can be fully applied, maintenance costs and parts replacement times can be significantly reduced, equipment failures can be reduced, machine life can be prolonged, and friction loss can be reduced. Among them, the benefits of reducing maintenance costs and parts replacement times are particularly significant (up to 45%).

On September 18, 2002, the State Economic and Trade Commission, the Commission of Science, Technology and Industry for National Defense, the Ministry of Railways, the Ministry of Communications, the Ministry of Education, the State Environmental Protection Administration and other relevant departments hosted the product appraisal meeting of "Metal Wear Self-repairing Materials" in Harbin. The appraisal committee composed of Xu, Zhong Qunpeng, Ding Chuanxian, Zhang Fuze and other 17 experts unanimously agreed that the project passed the appraisal:

Self-repairing material for metal wear is a high-tech product with independent intellectual property rights, which has advanced level in the world.

"The successfully developed self-repairing materials for metal wear have broad application prospects, which can promote the applied basic research in the field of surface engineering and tribology in China, and at the same time promote the upgrading and transformation of traditional industries in China, which will have a significant impact on the development of China's national economy." After the appraisal meeting, the State Economic and Trade Commission included the project in the national science and technology innovation plan of 2002-20 16.

In-situ self-repair technology of metal wear is a world-leading high-tech technology, which is of great significance to realize the two strategic goals of human sustainable development, namely energy saving and environmental protection. With the popularization and application of this technology, it will certainly produce great economic and social benefits in China.

China has successfully developed the world's advanced self-repairing materials for metal wear.

Building materials network, China [2002- 12-26]

Harbin has recently developed a new material, which can quickly reach the friction surface of metal by adding a very small amount of carrier lubricating oil, automatically repair the worn parts, and make the internal combustion engines of cars and ships overhaul for life.

Experts jointly organized by the State Economic and Trade Commission, Ministry of Communications, Ministry of Railways and other departments believe that the self-repairing material for metal wear can form a cermet layer with high smoothness and hardness on the friction surface of metal, so that the worn metal parts can be automatically repaired in the normal operation of mechanical equipment and restored to the prototype size, which has reached the international advanced level.

Jin, an internationally renowned expert in tribology and a professor at the State Key Laboratory of Tribology in Tsinghua University, said that this is a major breakthrough in the research of wear reduction mechanism and product development in the field of tribology in China and a revolution in the maintenance technology of mechanical equipment.

Dong, the inventor of the patent for self-repairing materials for metal wear and a researcher at China Kelian Economic Development Research Center, said that the self-repairing materials for metal wear and tear were successfully developed on the basis of absorbing the advanced technology of metal friction at home and abroad, combined with the types and grades of ores in China, and can be widely used in electromechanical manufacturing, metallurgy, petroleum, chemical industry, railways, aerospace, precision parts processing and other fields.

The internal combustion engine of a train in Beijing Railway Sub-bureau was worn1.2000 km after overhaul. After the application of this new material, it was confirmed by the State Key Laboratory of Tribology in Tsinghua University that the internal combustion engine continued to run for 300,000 kilometers, and the original wear disappeared and returned to the prototype size. The newly overhauled locomotive directly uses this new material to travel 500 thousand kilometers and is still as good as new.

Expert tests show that this material can improve the rated service life of bearings by more than 265,438+0 times while maintaining the best dimensional accuracy. The service life of the cutter is increased by more than 5 times; The service life of special steel has been increased by 1 times.

At present, Harbin Shenglong New Materials Technology Co., Ltd. has built the first production line of self-repairing materials for metal wear in Harbin.

According to experts, wear, corrosion and fatigue are the main forms of failure of mechanical materials, and the economic losses caused by short life and high energy consumption of various mechanical equipment alone are as high as hundreds of billions of yuan in China. The appearance of metal wear self-repairing materials can make all kinds of mechanical equipment be maintained without disassembly, greatly prolonging its service life, which is of great significance for China to embark on a new road of industrialization with high technology content, low resource consumption and good economic benefits.

World's top technology, brand-new friction concept

Author: Titan Date: February 27, 2007 13: 29: 00

A "self-repairing material for metal wear" with independent intellectual property rights has been widely used in various construction machinery and equipment in China for more than two years and achieved satisfactory results. This kind of trace powder material added to lubricating oil can form a cermet layer with excellent wear-resisting and friction-reducing performance on the iron-based metal friction surface, which greatly improves the microhardness and smoothness of the friction surface, and the dry friction coefficient under oil-free lubrication is one order of magnitude lower than that under oil film lubrication. At the same time, the use method is particularly simple, which can complete the self-repair of the worn parts in the process of mechanical operation and restore them to the prototype size, thus greatly prolonging the service life of the construction machinery and reducing the friction resistance and energy consumption.

1, a revolutionary technology in the field of surface engineering

Automatic repair technology of metal wear is a revolutionary new technology in the field of surface engineering. The application of this technology can not only prevent the wear of parts, but also repair the worn surface of the machine in long-term operation, thus greatly prolonging the service life of machinery and equipment and reducing energy consumption, which can not be achieved by the existing surface treatment and surface protection methods and various oil additives sold in the market.

This technology can be applied to any kind of mechanical equipment with mechanical friction, which is the first of its kind in China. Tested by Tsinghua University State Key Laboratory of Tribology, National Bearing Quality Supervision and Inspection Center and many other scientific research and testing institutions, on September 18, 2002, the State Economic and Trade Commission, together with the Science, Technology and Industry Committee for National Defense, Ministry of Railways, Ministry of Communications, Ministry of Education, State Environmental Protection Administration and other relevant departments, hosted the "Appraisal Meeting of Metal Wear Self-repairing Materials" in Harbin. The appraisal committee, composed of 7 experts including Xu, Zhong Qunpeng, Ding Chuanxian and Zhang Fuze from China Academy of Engineering, unanimously passed the product appraisal of "Metal Wear Self-repairing Material" with independent intellectual property rights. On June 5438+February 65438+February 7, 2002, Beijing Municipal Science and Technology Commission passed the appraisal of scientific and technological achievements of "Research on the Application of Metal Wear Self-repairing Materials in Diesel Engine of Diesel Locomotive". On June 2, 2003, the Science and Technology Committee of Beijing Railway Bureau passed the evaluation of the technical achievements of "Application Test of Metal Wear Self-repairing Materials", and clearly put forward the further comprehensive promotion and application.

2. Achievements of antifriction technology of construction machinery-"Metal wear self-repairing material"

"Metal wear self-repairing material" is an ultrafine particle material composed of magnesium hydroxysilicate and other complex components. In the running state of the equipment, lubricating oil (or grease) is used as a carrier to transport ultrafine particles to the friction working surface of the equipment. For the worn part, under the action of micro-local high temperature (flash temperature) caused by friction cutting force and particle grinding shear force, the particle material and the iron-based metal on the friction surface undergo thermochemical and mechanochemical replacement reactions, forming a high-smoothness iron-based silicate cermet layer. The thermal energy generated by friction makes the cermet layer grow continuously until it returns to the best fit gap. At this time, the heat energy generated by friction vibration and grinding in this part is greatly reduced, and the chemical reaction stops, completing the repair process of the worn part by granular materials.

"Metal wear self-repairing material" is not a common lubricant additive. It is different from all kinds of metal antiwear agents currently on the market. It does not form a protective layer by film forming technology or micro-infiltration technology, nor does it produce a ball antifriction layer. Instead, a cermet layer with excellent antifriction performance and extremely high microhardness is directly generated at the part where friction energy is converted into heat energy. Suitable for all kinds of iron-based metal friction pairs, as well as iron-based, copper and aluminum alloy friction pairs. It is a revolutionary new surface engineering technology in the field of metal wear. This technology is in a leading position in the world.

This first self-repairing material for metal wear in China was successfully developed by Harbin Shenglong New Materials Technology Co., Ltd. The company has the first automatic production line for art products in China, and has obtained a national invention patent. China National Intellectual Property Administration has accepted six related invention patent applications.

3. The wide application of art will bring great economic and social benefits.

The energy output from 1/3 to 1/2 in the world is consumed by friction. About 70% of human production activities to reduce resources and energy consumption focus on saving energy and improving the reliability of equipment operation.

Wear, corrosion and fatigue are the three main forms of material failure. The economic loss caused by wear and tear is very huge. In the United States, the economic losses caused by friction and wear exceed $200 billion every year. According to the incomplete statistics of metallurgical mines, agricultural machinery, coal, electric power and building materials in China, the material loss and energy waste caused by friction and wear are as high as 654.38+0 billion yuan every year. According to statistics from other departments, China's annual losses caused by friction amount to hundreds of billions of yuan. Compared with developed countries, the same industrial output value in China has high energy consumption and short service life of machinery and equipment, which leads to great waste of resources in China. Therefore, saving energy and reducing consumption has always been the goal of industrial development in China.

Taking the bearing industry as an example, a large number of bearings need to be imported from abroad every year because the service life and other performance indexes of bearings in China can not meet the use requirements. 1999 imported about 640 million sets of bearings, valued at 346 million dollars; In 2000, about 920 million sets of bearings were imported, valued at 445 million dollars. In 20001year, about 725 million sets of bearings were imported, valued at 489 million dollars. These bearings are mainly used in textile machinery, machine tools, mining and petroleum machinery, household appliances and automobiles. Although the accuracy of bearings produced in China can reach the level of similar products in the world, due to the influence of steel quality and heat treatment technology, the service life of bearings still cannot reach the level of imported bearings.

Tested by the National Center for Bearing Quality Supervision and Inspection, the 6206-2RSIXI bearing treated with "metal wear self-repairing material" can still maintain its initial rotation accuracy and pre-test clearance when the test life reaches 2 1 time, and the raceway and roller surfaces are basically free of wear. The experimental results show that the use of "metal wear self-repairing material" can not only greatly improve the life of the bearing, but also keep its rotation accuracy unchanged or restore it. Therefore, the utilization rate of mechanical equipment can be significantly improved. The application of this project will not only greatly reduce the import of bearings in China and save foreign exchange expenses, but also make China a big exporter of bearings. For China's bearing industry, this is a major technological progress, with huge economic benefits, which can comprehensively improve the quality of household appliances, automobiles, textile machinery, petrochemical machinery, mining machinery, machine tools and other products.

Taking the transportation industry as an example, the lubricating oil of DF- 1 1 diesel locomotive is added with "self-repairing material for metal wear", which accounts for about 200,000 parts of the lubricating oil. After the decomposition test of 27 diesel locomotives after running for 300,000 kilometers, the dimensions of easily worn parts such as cylinders, pistons and piston rings still meet the tolerance requirements of new products, which are called "self-repairing materials for metal wear". Therefore, Beijing Diesel Locomotive Depot decided to cancel the 300,000-kilometer intermediate repair course for participating locomotives and wait until the locomotive continues to run for 600,000 kilometers before conducting the test. After the initial test of three diesel locomotives, the fuel consumption rate is above 4%, with the highest being 9.6%. At present, the railway diesel locomotive 103, which uses "metal wear self-repairing material", is running normally on the trunk line of Beijing Railway Bureau.

"Metal Wear Self-repairing Material" has been tried on the 17 bus operated by the seventh branch of Beijing Public Transport Company, and the technical condition of the engine has been obviously improved. 1 engine 12000 km after sampling, the roundness deviation value in the middle of the cylinder barrel has been recovered to varying degrees, and decreased by more than 50%. The pressure of each cylinder generally rose, with an average increase of 20%. The phenomena of blowby and smoke in the experimental diesel engine disappeared. The average fuel consumption per 100 kilometers of diesel vehicles decreased by 7%, gasoline vehicles decreased by 4%, the engine failure rate decreased, and the intact rate increased.

China is a big oil importer. Cars, ships and railway diesel locomotives all use fuel as energy. Diesel locomotives in China consume more than 5 million tons of fuel every year. If the "metal wear self-repairing material" is used, the locomotive fuel consumption will be reduced by 4%, and the fuel consumption will be saved by 200,000 tons every year. The mileage of medium-repair of internal combustion engines is extended from 300,000 km to 500,000-600,000 km, which can also save a lot of spare parts, minor repairs and medium-repair every year, and improve the online utilization rate of locomotives (the repair rate is reduced 1%, which is equivalent to the transportation capacity of 150 diesel locomotives in China every day). If the application scope is further extended to the easy-to-wear systems such as axles, compressors and tracks, the resulting synthesis.

China alone has180,000 cars and millions of ships driven by internal combustion engines. The comprehensive economic benefits of using "metal wear self-repairing materials" can reach tens of billions of yuan, such as reducing energy consumption, prolonging the life of friction and wear parts and improving the operating rate.

In addition, China also has bottlenecks in the fields of textile machinery, petrochemical machinery, mining machinery and metallurgical machinery. The life of refrigerators, washing machines, air conditioners, microwave ovens, electric fans, bicycles and sewing machines in China household appliances depends on the wear resistance and mute performance of their bearings. It is expected to solve the above problems after using "metal wear self-repairing material".

The wide application of "self-repairing materials for metal wear" will improve the competitiveness of China's industrial products, promote the development of related industries and have a great impact on the development of the national economy. At the same time, it will also promote the research of friction-reducing mechanism and the research and development of friction-reducing products in the field of tribology in China, which is of great significance for China to embark on a new road of industrialization with high technology content, low resource consumption and good economic benefits and realize the two strategic goals of human sustainable development, namely energy conservation and environmental protection.

Previous article:Jiangyin Tianjiang Pharmaceutical Co., Ltd. recruitment information, how about Jiangyin Tianjiang Pharmaceutical Co., Ltd.?
Next article:Haimen Power Grid Staff Salary