Ways to reduce friction losses :

XADO TECHNOLOGY modifies friction surfaces. This is a brand-new, environmentally friendly, energy saving technology for the equipment 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 materialsChanging 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 400 000 km extra.

Test period - 300 hours after XADO revitalizant applicationXADO laboratory testCircular lubricating, oil. Lubrication intensity - 3 drops per secondLaboratory friction machine

Material

Dimensions, mm

Surface hardness

Roughness (Ra)

Roller

. 45

12.7 8

HV816

3.2

Disc

. 45

70 3

HV270

0.8

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 tracesFriction machine1- before test2- after test

Tables and diagrams of nanohardness of wear traces on the disc surface at a depth of 50 nm and 20 nmAfter 300 hours of tests on the friction machine

20 nm

Test number

1

2

3

4

5

6

7

8

9

10

Avg. value

Nanohardness (GPa)

13.6

16.5

14.6

15.8

10.7

12.5

12.2

15.0

15.8

16.5

14.5

50 nm

Test number

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

average

Nanohardness(GPa)

7.9

8.8

18.1

16.7

20.5

13.1

9.7

6.4

4.6

8.2

5.8

7.6

7.3

15.8

7.8

10.2

Table of measurements and a diagram of nanohardness of the roller friction surface at a depth of 50 nm after tests on the friction machine300 hours of roller operation during test period

50nm

Measurement number

1

2

3

4

5

Avg.value

Nanohardness (Gpa)

17.5

16.5

16.4

17.3

14.9

16.7

Table of measurements and a diagram of nanohardness of the 12V- 90 diesel engine cylinder (Sheng Li Oilfield) at a depth of 50 nmOperating time of the engine in excess of the planned rate -2000 hours

50nm

Measurement number

1

2

3

4

5

Average value

Nanohardness (Gpa)

17.1

10.6

16.0

19.0

18.4

17.2

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 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 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%C11.32%C

Photos of the sample with different enlargement, cross section of 12V- 90 diesel engine cylinder surface, drilling rig. cylinder material; XADO surface layer; 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: at a depth of 6 micron on the cylinder surface (XADO metalloceramics layer) protective rubber (special sample for analysis)

Element

Weight%

Atomic%

C K

2.29

7.95

O K

6.34

16.54

Si K

10.38

15.42

Mn K

1.86

1.41

Fe K

74.47

55.62

Cu K

4.65

3.05

Totals

100.00

Element

Weight%

Atomic%

C K

2.16

7.09

N K

9.36

26.33

Si K

6.28

8.81

Mn K

1.04

0.75

Fe K

78.71

55.51

Cu K

2.45

1.52

Totals

100.00

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.

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

Name of the element

C

O

Mg

Fe

Si

Ca

Zn

Element content, %

42.32

33.66

10.70

5.84

3.87

2.42

1.18

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 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; 16-72 hours of operation oil containing XADO). % - wear, h hours of operating;

Practical examplesof wear restorationusing 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 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 locomotive engine after treatmentand 410000 km run

Main journals of the crankshaft 230 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 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 loco