Metal self-repair technology (Mosheng technology? ) Applications in equipment management and maintenance

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Is metal self-repair technology applied in equipment management and maintenance? For example, when a bearing failure is detected and it’s not possible to stop the machine for repairs immediately, adding a metal self-healing agent can improve the bearing’s condition, allowing it to hold up until the machine can be stopped for repair and thus avoiding the losses associated with unplanned shutdowns. A foreign engineer recommended to me an American-based repair agent that is not available in China; the website is http://www.proteclubricants.com/industrial/afmtxl_17.html – you can take a look there. The domestic MoSheng technology won an award at the World Maintenance Conference; the technology it claims to utilize is likely metal self-repair technology. I wonder whether it is being used in equipment maintenance and management practices, and what the results are Below are the introductions to \"Metal Self-Healing Technology\" and \"Moseng Technology\" taken from Baidu Baike. Metal self-healing technology is currently a cutting-edge technique in the world; it has already been granted a **patent. Its emergence in the field of friction has changed people’s traditional way of thinking: \"It was previously believed that during movement, metal friction surfaces would experience friction, heat generation, fatigue, and wear.\" ”People's views have changed due to the emergence of a new technology. This is metal self-repair technology. As a result, friction, heat generation, and mechanochemical effects lead to metal self-repair. 　　Wear, corrosion, and fatigue are the three main forms of failure in mechanical materials. The economic losses caused by wear are enormous; in the United States, the economic losses resulting from frictional wear exceed 200 billion dollars per year. It is estimated that China incurs losses amounting to hundreds of billions of yuan per year due to friction and wear. Therefore, energy conservation and consumption reduction have always been goals pursued in the industrial development of our country and the world as a whole. 　　 As a completely new type of material for reducing friction in mechanical equipment and parts, \"metal wear self-repairing materials\" are ultra-fine powder composite materials composed of various mineral components such as magnesium hydroxysilicate, along with additives and catalysts. The particle size of its common components ranges from 0.1 to 10 rm, and it can be added to various types of lubricants or greases. Lubricating oil or grease acts as a carrier to deliver the fine powder particles of the repair material to the working surface of the frictioning parts. It does not undergo chemical reactions with oils, does not change the viscosity or properties of oils, and has no toxic side effects. Its features are as follows: without disassembling the mechanical equipment, it is possible to carry out self-repair of the worn areas made of ferrous metals while the equipment is in operation. This results in the formation of a cerametallic protective layer with excellent anti-wear properties, which increases the hardness and surface finish of the friction surfaces, significantly reduces the coefficient of friction, and restores the worn areas to their original dimensions. As a result, the service life of the equipment is greatly extended, and energy consumption is reduced. Applying this new technology not only prevents component wear but also enables the automatic repair of the worn friction surfaces of components under long-term operation, offering broad application prospects. 　　 Taking bearings as an example, the precision of bearings produced in China has reached the level of similar international products. However, due to factors such as steel quality and heat treatment processes, there is still a certain gap between the service life and fatigue resistance of these bearings and international standards. According to tests conducted by the **Bearing Quality Supervision and Inspection Center**, the 6205-2RS1×1 bearings that use \"metal self-repairing materials\" were able to reach 13 times their rated service life, while still maintaining their rotational accuracy and the clearance they had before testing; there was virtually no wear on the raceways of the rings or on the rolling elements. This experiment shows that the use of “metal wear self-repairing materials” can extend the lifespan of bearings, maintain product precision, and restore it. This helps to reduce accidents and significant losses caused by bearing failures in mechanical equipment, decreases the downtime for maintenance, and improves the utilization rate of the equipment. This has significantly reduced the import of bearings, saved foreign exchange, and created conditions for our country to become a major exporter of bearings. Currently, this technology has begun to be tested and promoted in some bearing manufacturers, and has already been applied to certain automotive bearings and machine tool spindle bearings. 　　 The lifespan of rotating components in refrigerators, washing machines, air conditioners, electric fans, etc., also depends on the wear resistance of the bearings. Using \"self-healing materials for metal wear\" will help enhance the competitiveness of home appliances and enable them to better enter international markets. 　　 In the field of transportation, cars, trains, and ships that rely on fuel as an energy source experience internal wear in their internal combustion engines over time, along with an increasing fuel consumption rate. The use of \"self-healing materials for metal wear\" can reduce component wear, extend the lifespan of engines, lower fuel consumption, and improve operational efficiency, resulting in economic benefits worth billions of yuan each year. 　　 Furthermore, in China’s industries such as textile machinery, petrochemical machinery, mining machinery, and metallurgical machinery, there is a \"bottleneck\" in the form of short wear life of mechanical components, which hinders the proper operation of these devices and prevents an improvement in system reliability. “The application of \"metal wear self-repairing materials\" can break through these \"bottlenecks\", enhance the reliability and efficiency of system operation, save energy and reduce consumption, yielding significant overall benefits. 　　 In short, the widespread application of \"metal wear self-healing material\" technology will enhance the competitiveness of China’s industrial products, spur the development of related industries, and have a significant impact on the growth of the national economy. At the same time, it also elevates China’s academic research on anti-wear technologies as well as the development of anti-wear products to new heights, which is of great significance for achieving the two strategic goals of energy conservation and environmental protection in human sustainable development. Mosheng – Principle of Action: The basis of Mosheng technology is the Mosheng friction surface regenerator, which is a mixture composed of various dispersed, extremely fine minerals, along with various additives and catalysts (Know-How). Generally speaking, the MoSheng friction surface regenerator uses a lubricant as a carrier and is added to any type of lubricant; however, it does not undergo any chemical reaction with the lubricant nor does it change its viscosity. It is not a lubricant additive or a metal repair agent in the ordinary sense. MOSAN is a cutting-edge metal superfinishing technology that enables metals to possess exceptionally excellent physical properties. During the initial stage of using Mosheng technology, superfinishing running-in of the contact surfaces occurred. The diffusion of Mo into the interior of the metal parts improves the crystal structure of the metal itself, thereby strengthening its surface layer. Under the extremely high temperature and pressure at the local contact points, MoS2 particles \"fuse\" into the lattice of the metal surface layer; simultaneously, synthesis hardening occurs in the depressions caused by microscopic irregularities, involving MoS2 particles, metal particles, and other materials involved in friction. Therefore, when using MoSaint to treat mechanical equipment, a cerametallic structure is formed on the lattice of the metal friction surfaces. The thermodynamic processes in the frictional contact area lead to the formation of thicker cerametallic layers in areas where metal wear is greater (an increase in the thickness of the cerametallic layer was measured at 1.5 mm in gear assemblies, 0.2 mm in ring-and-bush friction pairs, and 0.02 mm in high-pressure oil pump plunger pairs). A prominent feature of the aforementioned repair process is its self-regulating capability, as the repair action takes place simultaneously on both contact surfaces under the same load. As the cerametal layer is formed, the friction between the contact surfaces begins to decrease sharply, and the energy required to activate the frictional effect also decreases accordingly. When the gap at the contact points across the entire friction surface approaches an optimal value, the aforementioned repair process gradually stabilizes ； The process comes to an end when the energy generated by friction drops low enough. At this point, the original \"metal-metal\" friction mode at the contact points changed to \"cerametal-cerametal\". Due to the identical and extremely high microhardness of the resulting friction surfaces, coupled with their very low roughness, it possesses outstanding anti-friction and wear-resistant properties. Under certain specific conditions, machinery and equipment treated with this technology can even withstand \"dry friction,\" meaning they can operate without the use of any lubricants. Abroad, an automobile engine that has been treated with MoSheng has now accumulated an oil-free operating distance of 8,000 kilometers. In China as well, numerous oil-free tests have been conducted on automobile engines treated with MoSheng; for example, the engine of a Xiari taxi that had been in use for 6 years and had covered over 300,000 kilometers remained intact after running for 660 kilometers without any oil, thanks to the MoSheng treatment. This oil-free test was carried out under the supervision of automotive experts from authoritative institutions, and was notarized, thereby once again proving the excellent wear resistance of the MoSheng metal-ceramic coating. The repair process of Mosheng Regenerator has another important feature, namely the accumulation of repair effects. Its essence lies in the excess Mo Sheng repair agent left over from the previous treatment, which can be used to carry out repairs promptly as the protective layer wears down in the future. In other words, increasing the dosage of MoS2 used at any time is a protective measure that will not cause the friction pair to stick, as the repair takes place during motion and under the same conditions on the surfaces of the friction pair. As is evident from the above description, the partial wear of the protective layer that occurred after the last repair using the Mosei regeneration agent can be fully restored by adding a small amount of it again; by repeating this process multiple times, it is possible to achieve lifetime maintenance-free operation for engines and other mechanical equipment. Furthermore, the effectiveness of MoSheng regenerator is not lost when the lubricant is changed, for two reasons: first, the ceramic-metal layer formed possesses excellent anti-friction properties; second, MoSheng remains active for a considerable length of time at the metal friction surfaces. In terms of the performance of automotive engines, the stability of the MoSheng ceramic-metal layer lasts for at least 150,000 to 200,000 kilometers. Technical features: Compared with conventional lubricant additives and surface engineering techniques, it enables in-situ, tool-free repair. The process is simple and requires no special equipment. With MoSheng technology, no equipment is needed, nor any pretreatment; it does not cause any deformation of the parts, nor any changes in their structural organization or mechanical properties. No post-processing is required either – simply adding MoSheng particles to the lubricant or grease is sufficient to achieve tool-free repair. —It possesses adaptive repair capabilities, automatically maintaining an appropriate gap. The repair of the friction surface takes place under certain operating conditions (load, speed, temperature, etc.). The more severe the wear on the original surface, or the harsher the operating conditions, the thicker and more extensive the modified repair layer will be; conversely, it will be thinner and less extensive. Thus, the repair layer has a \"filling and compensating\" effect, which enables the friction pair to maintain an appropriate gap. This is something that no surface technology can achieve. —It has wide applicability and can be used in any metal friction pair. It can be applied to lubricated metal friction pairs in any mechanical equipment, whether they are made of ferrous or non-ferrous metals, to exert its effect. Its range of applications is broader than that of any other surface treatment technique; it can even replace some existing surface treatment methods, such as various chemical heat treatments and surface texturing processes. —No pollution at all – it is a truly green remanufacturing technology. Since MoSheng technology does not require the use of any process equipment, chemical reagents, or harmful gases that could cause pollution to varying degrees, and the MoSheng particles themselves are made from green materials that contain no harmful substances ； By using MoSheng technology, it is possible to significantly reduce the emission of harmful gases, as well as vibration and noise from mechanical equipment; thus, it is a completely green remanufacturing technology. Reposted – http://www.mosheng.com/ This post was last edited by wolf309 on 2009-3-13 14:56 ]