XADOTechnology_2006_Eng

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 400 000 km extra.

XADO laboratory test Laboratory friction machine Test period - 300 hours after XADO revitalizant application

Circular lubricating, oil.

Lubrication intensity - 3 drops per second

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

Frictio n machine

HV Hardness / MPa

Table of disc surface hardness on the wear traces

5gf

500 400 300 20gf

200 100 0

1- before test 2- after test

1 1--before test

2 2--after test

22 20 18 16 14 12 10 8 6 4 2 0

After 300 hours of tests on the friction machine

压 痕 深 度 50nm

平均值 10.2

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Number

Nano Hardness/Gpa

Nano Hardness

Tables and diagrams of nanohardness of wear traces on the disc surface at a depth of 50 nm and 20 nm 18 16

平均值

14

14.5

12 10 压 痕 深 度 20nm

8 6 4 2 0

0

1

2

3

4

5

6

Number

7

8

9

10

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

压 痕 深 度 50nm

17.5

Nano Hardness/Gpa

300 hours of roller operation during test period

17.0

平均值

16.5

16.7

16.0 15.5 15.0 14.5

0

1

2

3

Number

4

5

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

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.

12 9 6

16.7Gpa

14.5Gpa

17Gpa

17Gpa

齿 面 磨 痕

缸 套 磨 痕

4

5

(压 入 深 度 20nm)

15

纳

米

硬

/ 度 Gpa

18

10.2Gpa (压 入 深 度 50nm)

圆 盘 磨 痕

小 圆 柱 磨 痕

圆 盘 磨 痕

3 0 1

2 摩

擦

3 副 种

类

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

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 nanoroughness with atomoscop Cylinder liner of the 12V- 90 engine Ra=44nm

Gear tooth of the water pump Ra=50nm

Measurement of surface nanoroughness with 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%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 micron В – 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

ÂŤRamanÂť device

Friction machine roller Results of the measurements in the second point (cavity in form of a scratch)

ÂŤRamanÂť device

Friction machine roller - result of the measurements in the third point (cavity in form of a pit)

ÂŤRamanÂť 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.

0.0 1000

900

800

700

600

500

400

300

200

-Fe 3p

-Si 2p-Fe 3s

-Si 2s

0.5

-Cl2p

-Rh3d5 -Mg KLL -Rh3d3-Rh3d -C1s

-Ca 2p -Ca 2p3-Ca 2p1

-N 1s

-Ca 2s

-O 1S

-Zn LMM -Rh 3p3

1.0

-Fe 2P1 -Fe 2P -Fe 2P3

1.5

-Fe LMM

c/s

2.0

-Fe LMM1

2.5

5

-Fe LMM2

× 10

-o KLaL

Results of analysis of the friction machine roller photoelectron spectrum (XPS – analysis)

100

Binding Energy(eV)

Chart of the photoelectron spectrum elements. XPS - analysis

0

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 ÂŤ0Âť, 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; 0.070 0.065 0.060 0.055

Ä¥ËðÂÊ (%)

0.050 0.045 0.040 0.035 0.030 0.025 0.020 0.015 0.010

在原来润滑油的

加普通

0.005

基础上加摩圣凝胶

润滑油

0.000 0

8

16

24

32

40

ʱ¼ä(h)

48

56

64

72

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 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 treatment and 410000 km run Main journals of the crankshaft Φ230 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 Φ210 мм №1 №3 №5 №7 (initial) (mid-life repair)

-0.009 -0.006

-0.006 -0.007

-0.015 -0.014

-0.021 -0.023

Measurements of crankshaft journals of the DF 8B locomotive engine after treatment and 600 000 km run Wear of the main journals of the crankshaft Φ230 mm, mm

№1

№3

0.007

-0.002

№5 -0.006

№7 -0.002

№9 -0.006

Wear of the Rod journals of the crankshaft Φ210 mm, mm

№1

№3

№5

№7

-0.001

0.002

-0.001

0.003

Sheng Yang province, China Aircraft engines producing plant ÂŤRassvetÂť.

Coordinate boring machine, vertical-type machine, produced in France.

Results of the spindle vibration level measurements after XADO treatment Spindle vibration, vertical(mm)

Spindle vibration, horizontal (mm)

Spindle revolutions (rpm)

Time of operation after XADO treatment (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

Date of the measurement

XADO products in comparison with regular oils have a fundamental difference in working surface modification

Molecular structure of different oil additives

Chemically active substances

Surface-active substances

Anti-burr additives

Boundary friction Liquid friction

Boundary friction of the surface

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 Đ?6 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, 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.

03-36 03-24 03-12

Photos of oil samples in the friction machine containing iron particles

03-48 03-60

Bewick State registration number â„– H68675

Oil volume of each sample – 1 ml.

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,H686751600,H68675-3600; H68675-6600

FerrograpHic Analysis ResultsďźˆH68675 Sample Number Distance run (km) Quantity of large particles DL Quantity of small particles, DS Is=DL(DL-DS)

H68675-

H68675-

H68675-

H68675-

H68675-

450

600

1600

3600

6600

450

600

1600

3600

6600

21.9

43.0

41.6

23.7

17.0

12.1

31.1

27.1

9.4

8.5

214.62

511.7

603.2

338.91

144.5

1600

600

Relation between

400

Is

intensity of H68675

600

500

3600

300

engine wear and the

200

distance run

100

450 6600

0

1000 2000 3000 4000 5000 6000 7000 running distance / km

1600

450 600 3600

Photos of H68675 engine oil samples

6600

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.

Thank you for your attention!