Advanced Surface Engineering Technologies for Remanufacturing
Advanced Surface Engineering Technologies for Remanufacturing
Advanced Surface Engineering Technologies for Remanufacturing
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<strong>Advanced</strong> <strong>Surface</strong><br />
<strong>Engineering</strong> <strong>Technologies</strong> <strong>for</strong><br />
<strong>Remanufacturing</strong><br />
Hanshan Dong<br />
Birmingham <strong>Surface</strong> <strong>Engineering</strong> Group<br />
The University of Birmingham
UK - China Joint Project<br />
‘Towards long-life remanufactured heavy-duty gears
<strong>Surface</strong> <strong>Engineering</strong><br />
@ Birmingham<br />
• The world’s 1st surface engineering group (1983)<br />
- Wolfson Institute <strong>for</strong> <strong>Surface</strong> <strong>Engineering</strong> (WISE).<br />
• International journal, <strong>Surface</strong> <strong>Engineering</strong>, was<br />
launched by WISE and Institute of Metals in 1985<br />
• The world’s premier research centres in<br />
surface engineering
National Key-Libratory<br />
<strong>for</strong> <strong>Remanufacturing</strong><br />
Beijing, PR China
1. <strong>Remanufacturing</strong> <strong>Engineering</strong><br />
<strong>Remanufacturing</strong> engineering involves a<br />
series of surface engineering technologies to<br />
restore or improve the per<strong>for</strong>mance of failed<br />
components.<br />
• Improved per<strong>for</strong>mance<br />
• Prolonged service life<br />
• Reduced investment<br />
• Energy saving<br />
• Materials conservation<br />
• Reduced environmental impact
<strong>Remanufacturing</strong> planetary frame<br />
by plasma spraying<br />
Cost Reduction – 90%<br />
Materials used – 1%<br />
Service Life – 200%
Engine <strong>Remanufacturing</strong>
Economic & Energy Benefits<br />
(10000 Stial Engines per year)<br />
Reduced<br />
Investment<br />
Reused<br />
Material<br />
Energy<br />
Saving<br />
£30M<br />
8500t<br />
6 x10 10 kJ<br />
(Sinotruk Jinan Fuqiang Power Co)
Part II<br />
<strong>Advanced</strong> <strong>Surface</strong><br />
<strong>Engineering</strong> <strong>Technologies</strong> <strong>for</strong><br />
<strong>Remanufacturing</strong>
<strong>Remanufacturing</strong> surface technologies<br />
(1) High-velocity arc spraying<br />
(2) Nano brush-plating technology<br />
(3) Active-screen plasma treatment
2.1 High-Velocity Arc Spraying Technology<br />
Principles of Electric-Arc Spray
High-Velocity Arc Spraying Technology<br />
Based on the traditional<br />
arc spraying, the high-velocity<br />
arc spraying technology<br />
(HVAS) was developed. The<br />
coating prepared by HCAS<br />
possessed the character of<br />
compact microstructure, low<br />
porosity and high bonding.
Al/SS composite Coating<br />
Different metal wires, one stainless steel wire, one RE containing<br />
aluminum wire were used to prepare the composite coating.<br />
+<br />
不 锈 钢 丝<br />
Stainless<br />
steel wire<br />
熔 滴<br />
droplets<br />
涂 层<br />
coating<br />
雾 化 气 体<br />
tomization gas<br />
基 体<br />
Substrate<br />
-<br />
铝 丝<br />
Aluminum<br />
wire<br />
电 弧<br />
arc
Main-Bearing & Connecting-Rod Journals<br />
Application Examples<br />
Main-Bearing Bores
2.2 Nano Brush-Plating<br />
Technology
Brush/Selective Plating
Nano Composite Coatings<br />
Nano Particles:<br />
n - Al 2 O 3<br />
n - SiC<br />
n - diamond
<strong>Surface</strong> Morphologies<br />
(a)<br />
(b)<br />
Nickel coating<br />
(60-120µm)<br />
n-Al 2 O 3 /Ni coating<br />
(20-60 µm)
n-Al2O3/Ni<br />
Microstructure (BF) and diffraction pattern<br />
TEM analysis<br />
Ni<br />
(420)<br />
(331)<br />
(400)<br />
(222)<br />
(311)<br />
(220)<br />
(200)<br />
(111)<br />
α−Al2O3<br />
(006)<br />
(110)<br />
(300)<br />
(008)<br />
Composite coating composed of 10-30nm equiaxed Ni and Al2O3 grains
Interface<br />
Ni nano crystal<br />
Nano particles<br />
Ni matrix<br />
Matrix Ni noncrystal<br />
Nano particle<br />
HRTEM micrographs showing good bonding<br />
between nano particles and the Ni matrix.
Hardness of Nano Composite Coatings<br />
700<br />
600<br />
Hardness, HV0.05<br />
500<br />
400<br />
300<br />
200<br />
100<br />
0<br />
Ni/n-Al2O3<br />
Ni/n-SiC<br />
Ni<br />
0 100 200 300 400 500 600 700<br />
Temperature, degree C
Contact Fatigue Life<br />
10 6<br />
2.0<br />
Fatigue life / cycling<br />
1.5<br />
1.0<br />
0.5<br />
0.0<br />
0 10 20 30 40<br />
Content (g/L)<br />
The contact fatigue cycle vs the content of Al 2 O 3<br />
in solution(test stress 300Kgf/mm 2 )
Application Examples<br />
Camshaft
Auto-brush-electroplating
2.3 Active-Screen Plasma<br />
<strong>for</strong> duplex remanufacturing
Heavy-Duty Gears<br />
Max contact stress: 2200MPa<br />
Low-carbon steel: 18Cr2Ni4WA<br />
Carburised: 1.3-1.8mm, HRC>57
<strong>Remanufacturing</strong> – laser cladding<br />
Powder: Fe-Mn-Cr-Mo
Failure of Remanufactured Gears
A DC Plasma Nitriding Unit<br />
+<br />
Furnace wall<br />
anode<br />
Component<br />
cathode<br />
D.C Power<br />
Component,<br />
cathode<br />
Furnace wall,<br />
anode<br />
Gas in<br />
Gas out<br />
_
Inside DC plasma nitriding (PN) furnace<br />
Plasma nitriding uses plasmas of nitrogen bearing gases
Uptake of PN units in Europe<br />
150<br />
France<br />
Number in Service<br />
100<br />
50<br />
0<br />
Germany<br />
Italy<br />
1970 1980 1990 2000<br />
Year<br />
UK<br />
Spain
Arcing<br />
Non-uni<strong>for</strong>m plasma<br />
C X Li
Gas in<br />
6-fan<br />
5-gas distributor<br />
4-furnace wall<br />
anode<br />
Re Drawing by<br />
C.X.Li<br />
13/07/01<br />
1 1<br />
2<br />
_<br />
3-metal screen<br />
cathode<br />
+<br />
Gas out
Gitter
• no arcing on parts<br />
• uni<strong>for</strong>m nitriding<br />
• no “hollow cathode”
Acknowledgement
Summary<br />
A series of advanced surface engineering<br />
technologies have been developed <strong>for</strong><br />
remanufacturing<br />
<strong>Remanufacturing</strong> will produce great<br />
technological, economic, ecological<br />
impact
Thank You!
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