Ways to reduce friction losses :

XADO – TECHNOLOGY modifies friction surfaces.

This is a brand-new, environmentally friendly, energy saving technology for the e

quipment maintenance and repair

Scientific research InstituteChin 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 planne

d rate.

This water pump gear shift of a locomotive was treated

by XADO and it ran 400 000 km extra.

Test period - 300 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:0 - 63 operating hours – load 10 kg;64 -158 operating hours – load 15 kg; 159 - 300 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 20

100

200

300

400

500

HV

H

ard

ne

ss

/ M

Pa

1--before test 2--after test

20gf

5gf

1- before test2- after test

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150

2

4

6

8

10

12

14

16

18

20

22

Number

Na

no

Ha

rdn

es

s

平均值 10.2

压痕深度 50nm

Tables and diagrams of nanohardness of wear traces on the disc surface at a depth of 50 nm and 20 nm

0 1 2 3 4 5 6 7 8 9 100

2

4

6

8

10

12

14

16

18

压痕深度 20nm

Na

no

Ha

rdn

es

s/G

pa

Number

平均值

14.5

After 300 hours of tests on the friction mac

hine

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

0 1 2 3 4 514.5

15.0

15.5

16.0

16.5

17.0

17.5 压痕深度 50nm

Number

平均值

16.7N

ano

Har

dn

ess/

Gp

a

300 hours of roller operation during tes

t 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 -2000 hours

1 2 3 4 50

3

6

9

12

15

18

圆盘磨痕

10.2Gpa

(压入深度 50nm)

纳米

硬度/Gpa

摩 擦 副 种 类

14.5Gpa

(压入深度 20nm)

16.7Gpa17Gpa 17Gpa

圆盘磨痕

小圆柱磨痕

齿面磨痕

缸套磨痕

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 cylind

er

Measurement number Ra, nm Rq, nm Rz, nm Rt, nm

1 23.67 36.26 732.7 928.99

2 29.39 38.94 473.3 830.6

3 27.14 40.2 934.15 2030

Average value

26.73 38.47 713.38 1263.20

Measurement of surface nanoroughnesswith atomoscop

Cylinder liner of the 12V- 90 engine Ra=44nm Gear tooth of the water pump Ra=50nm

Measurement of surface nanoroughnesswith atomoscop

Friction machine disc Ra=60nm Friction machine roller Ra=8nm

XADO metalloceramics layer is a thin colorless coating.

Its thickness can vary from 10 nm to several microns depending on the cond

itions 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%C 5.5%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 micronВ – on the cylinder surface (XADO metalloceramics layer)С – protective rubber (special sample for analysis)

7.09%C 7.95%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 rollerResults of the measurements in the second point (cavity in form of a scratch)

« Raman» deviceFriction machine roller - result of the measurements in the third point(cavity in form of a pit)

«Raman» deviceFriction machine roller. Result of the measurements in the forth point (separate area).

Laboratory analysis of the diamond-like layer

«Raman» deviceOn 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.

1000 900 800 700 600 500 400 300 200 100 00.0

0.5

1.0

1.5

2.0

2.5

-Fe 3

p-Fe 3

s

-Si 2

p

-Si

2s

-Cl2

p

-C1s

-Rh

3d

5-R

h3d

-Rh

3d

3-M

g K

LL

-Ca 2

p-C

a 2

p1

-Ca 2

p3

-N 1

s

-Ca 2

s

-Zn

L

MM -R

h 3

p3

-O 1

S

-Fe 2

P-F

e 2

P3

-Fe

2P

1

-Fe

LM

M

-Fe

LM

M1

-Fe

LM

M2

-o K

La

L

c/s

Binding Energy(eV)

× 105

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 cylinderMeasurement 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 workin

g 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; 16-72 hours of operation – oil containing XA

DO). % - wear, h – hours of operating;

0 8 16 24 32 40 48 56 64 720.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

0.065

0.070

加普通

润滑油

在原来润滑油的

基础上加摩圣凝胶

Ä¥Ë

ðÂ

Ê (

%)

ʱ¼ä(h)

Practical examplesof 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 th

e “ХАНИ” railway. After using XADO the locomotive ran extra

410 000 km and a mid-life repair was made. It ran 600 000 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 locomotiv

e engine after treatmentand 410000 km run

Main journals of the crankshaft 230 мм №1 №3 №5 №7 №9 (initial) -0.005 -0.010 -0.015 -0.009 -0.010

(mid-life repair) -0.010 -0.008 -0.009 -0.012 -0.004

Rod journals of the crankshaft 210 мм №1 №3 №5 №7

(initial) -0.009 -0.006 -0.015 -0.021

(mid-life repair) -0.006 -0.007 -0.014 -0.023

Measurements of crankshaft journals of the DF 8B locomotive engine aft

er treatmentand 600 000 km run

Wear of the main journals of the crankshaft 230 mm, mm

№1 №3 №5 №7 №9 0.007 -0.002 -0.006 -0.002 -0.006

Wear of the Rod journals of the crankshaft 210 mm, mm

№1 №3 №5 №7 -0.001 0.002 -0.001 0.003

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 (m

m)

Spindle revolutions

(rpm)

Time of operation after XADO treatme

nt(hours)

2002.11.07 0.050 0.020 10 0

2002.11.16 0.030 0.016 10 126

2002.12.02 0.018 0.009 10 382

2002.12.09 0.015 0.006 10 420

2003.01.22 0.012 0.005 10 800

XADO products in comparison with regular oils have a

fundamental difference in working surface modification

Molecular structureof 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, 2003. Sya Li taxi with 3-cylinder engine, city of Tyan Din. 660 km run, no breaking

2. April 14, 2004. 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, 2004. Volkswagen Jetta, ran without oil 108 km of the Pekin 5th 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,TiO2, SiO2, 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, f

orming 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 acc

ording to iron content in oil.

Photos of oil samples in the friction machine containing iron partic

les

03-12

03-24

03-36

03-60

03-48

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: H68675-450, H68675-600,H68675-1600,H68675-3600; H68675-6600

Oil volume of each sample –1 ml.

FerrograpHic Analysis Results（H68675）

Sample Number H68675-

450

H68675-

600

H68675-

1600

H68675-

3600

H68675-

6600

Distance run (km) 450 600 1600 3600 6600

Quantity of large

particles DL 21.9 43.0 41.6 23.7 17.0

Quantity of small particles,

D S 12.1 31.1 27.1 9.4 8.5

Is=DL(DL-DS) 214.62 511.7 603.2 338.91 144.5

0 1000200030004000500060007000100

200

300

400

500

600

Is

running distance / km

450

600

1600

3600

6600

Relation between inte

nsity of H68675 engi

ne wear and the dista

nce run

Photos of H68675

engine oil samples

450

600

6600

3600

1600

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 o

f the metalloceramics layer

Scheme of formation of XADO coating on friction surfaces

XADO metalloceramics layerXADO 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.

Thank you for your attention!