Hanshan Dong Birmingham Surface Engineering Group The University of Birmingham

Transcription

1 Advanced Surface Engineering Technologies for Remanufacturing Hanshan Dong Birmingham Surface Engineering Group The University of Birmingham

2 UK - China Joint Project Towards long-life remanufactured heavy-duty gears

3 Surface Birmingham The world s 1st surface engineering group (1983) - Wolfson Institute for Surface Engineering (WISE). International journal, Surface Engineering, was launched by WISE and Institute of Metals in 1985 The world s premier research centres in surface engineering

4 National Key-Libratory for Remanufacturing Beijing, PR China

5 1. Remanufacturing Engineering Remanufacturing engineering involves a series of surface engineering technologies to restore or improve the performance of failed components. Improved performance Prolonged service life Reduced investment Energy saving Materials conservation Reduced environmental impact

6 Remanufacturing planetary frame by plasma spraying Cost Reduction 90% Materials used 1% Service Life 200%

7 Engine Remanufacturing

8 Economic & Energy Benefits (10000 Stial Engines per year) Reduced Investment Reused Material Energy Saving 30M 8500t 6 x10 10 kj (Sinotruk Jinan Fuqiang Power Co)

9 Part II Advanced Surface Engineering Technologies for Remanufacturing

10 Remanufacturing surface technologies (1) High-velocity arc spraying (2) Nano brush-plating technology (3) Active-screen plasma treatment

11 2.1 High-Velocity Arc Spraying Technology Principles of Electric-Arc Spray

12 High-Velocity Arc Spraying Technology Based on the traditional arc spraying, the high-velocity arc spraying technology (HVAS) was developed. The coating prepared by HCAS possessed the character of compact microstructure, low porosity and high bonding.

13 Al/SS composite Coating Different metal wires, one stainless steel wire, one RE containing aluminum wire were used to prepare the composite coating. + 不 锈 钢 丝 Stainless steel wire 熔 滴 droplets 涂 层 coating 雾 化 气 体 tomization gas 基 体 Substrate - 铝 丝 Aluminum wire 电 弧 arc

14 Main-Bearing & Connecting-Rod Journals Application Examples Main-Bearing Bores

15 2.2 Nano Brush-Plating Technology

16 Brush/Selective Plating

17 Nano Composite Coatings Nano Particles: n - Al 2 O 3 n - SiC n - diamond

18 Surface Morphologies (a) (b) Nickel coating (60-120µm) n-al 2 O 3 /Ni coating (20-60 µm)

19 n-al2o3/ni Microstructure (BF) and diffraction pattern TEM analysis Ni (420) (331) (400) (222) (311) (220) (200) (111) α Al2O3 (006) (110) (300) (008) Composite coating composed of 10-30nm equiaxed Ni and Al2O3 grains

20 Interface Ni nano crystal Nano particles Ni matrix Matrix Ni noncrystal Nano particle HRTEM micrographs showing good bonding between nano particles and the Ni matrix.

21 Hardness of Nano Composite Coatings Hardness, HV Ni/n-Al2O3 Ni/n-SiC Ni Temperature, degree C

22 Contact Fatigue Life Fatigue life / cycling Content (g/l) The contact fatigue cycle vs the content of Al 2 O 3 in solution(test stress 300Kgf/mm 2 )

23 Application Examples Camshaft

24 Auto-brush-electroplating

25 2.3 Active-Screen Plasma for duplex remanufacturing

26 Heavy-Duty Gears Max contact stress: 2200MPa Low-carbon steel: 18Cr2Ni4WA Carburised: mm, HRC>57

27 Remanufacturing laser cladding Powder: Fe-Mn-Cr-Mo

28 Failure of Remanufactured Gears

29 A DC Plasma Nitriding Unit + Furnace wall anode Component cathode D.C Power Component, cathode Furnace wall, anode Gas in Gas out _

30 Inside DC plasma nitriding (PN) furnace Plasma nitriding uses plasmas of nitrogen bearing gases

31 Uptake of PN units in Europe 150 France Number in Service Germany Italy Year UK Spain

32 Arcing Non-uniform plasma C X Li

33 Gas in 6-fan 5-gas distributor 4-furnace wall anode Re Drawing by C.X.Li 13/07/ _ 3-metal screen cathode + Gas out

34 Gitter

35 no arcing on parts uniform nitriding no hollow cathode

36

37

38 Acknowledgement

39 Summary A series of advanced surface engineering technologies have been developed for remanufacturing Remanufacturing will produce great technological, economic, ecological impact

40 Thank You!