Experimental study on wear failure course of gas-valve/valve-seat in engine

The wear failure course of gas-valve/valve-seat in engine was investigated with a simulating tester. The results show that the failure of the contact conical surface is mainly caused by the elastic and plastic deformation and the fatigue micro-crack and spalling. The creep-deformation and corrosion atmosphere accelerated wear failure course at the high temperature. The wear failure course of the gas-valve/valve-seat in engine follows general wear rules of mechanical elements, but the rate of wear in the sharp wear stage is faster.     

Microstructure and wear resistance of electro-thermal explosion sprayed stellite coating used for remanufacturing

Electro-thermal explosion directional spraying was used to prepare the stellite coating on substrate of the AISI 1045 steel. The morphologies of cross-section and worn scar, porosity, distribution of elements, micro-hardness and wear resistance of the coating were determined by means of SEM, EDAX, micro-hardness tester and sliding wear tester. Because of the compact construction, good bonding and high hardness, the coating is characterized by good wear resistance. The results show that the mainly failure mode of the stellite coating is micro-plowing. Foundation item: Project(2003AA331130) supported by Hi-tech Research and Development Program of China; Project(50235030) supported by the National Natural Science Foundation of China     

Failure analysis used for remanufacturing of steel rolling components

The guide-pieces, used in the process line of steel rolling, were the important components. The guidepieces, which were slide contacting with the rolled-piece, had a high temperature and high speed. The wear was very serious. The results from failure analysis showed that there were three failure forms in the guide-pieces: the first was the wear during heat friction, the second was the heat fatigue under the cycle of deep heating and deep cooling, and the third was the impact rupture. Among them, the wear was the main reason. To the wear of guidepieces, there were four mechanisms, namely abrasive wear, adhesive wear, fatigue wear and corrosion wear. The failure analysis to the guide-piece laid the foundation for its remanufacturing. Foundation item: Project(50235030) supported by the National Natural Science Foundation of China     

Failure analysis of wear of main clutch separating ring of heavy vehicles

The severe wear of separating ring is considered to be a main reason which leads to the improper declutch of the main clutch of heavy vehicles. The wear mechanism of the separating ring is not well understood. Scanning electron microscopy and transmission electron microscopy were employed to analyze the surface features and dislocation characteristics of the separating ring. The typical features of furrows and rolled tongue-like metal were found on the surface of separating ring by scanning electron microscopy observation, which can be considered as a major indication of the grain-abrasion. A zone of high density dislocation was noted on the subsurface of the separating ring by transmission electron microscopy observation, which implies the contribution of the severe impact on the surface of the separating ring in the wear process. The influences of the structure of the separating ring, the service condition and the in-service stress distribution on the wear behavior, were also analyzed. The results show that the failure of separating ring results from the impact wear and grain-abrasion together with the plastic deformation. Foundation item: Project(41327040101) supported by the Pre-research Fund of General Armament Department; project(51489010104QT0101) supported by the Fund of State Key Laboratory of Re-manufacture Technology     

Automatic brush-plating technology for component remanufacturing

An automatic brush-plating system was developed for component remanufacturing. With this system, Ni/nano-alumina composite coatings from an electrolyte containing 20 g/L nano-alumina particles were prepared. Microstructure, surface morphology, microhardness and wear resistance of automatically plated coating and manually plated coatings were investigated comparatively. The results show that the automatically plated coatings are relatively dense and uniform and have lower friction coefficient of 0.089 under lubricant condition, when compared with manually plated coatings with friction coefficient of 0.14. Foundation item: Project(50235030) supported by the National Natural Science Foundation of China; Project(G1999065009) supported by the National Basic Research Program of China     

Morphology and tribological properties of Ni/n-SiO2 composite coatings by pulse-reverse current brush-plating

Ni/n-SiO₂ composite coating was electrodeposited by brush-plating with pulse-reverse current(RC). The morphology, hardness, and tribological properties of the coating were investigated and compared with those of Ni and composite coatings electrodeposited with direct current (DC). The results indicate that Ni/n-SiO₂ composite coating electrodeposited by RC, because of RC and the nano powders, has denser coating, finer crystal grains, higher hardness (HV650.0, nearly 1.5 times higher than that of Ni coating electrodeposited by DC) and lower friction coefficient (nearly 0.62), as a result, in the wearing experiment, the Ni/n-SiO₂ composite coating electrodeposited by RC has the least worn loss. So this kind of coating has better wear resistance. And RC electro brush-plating can be used as a new technology of brush-plating in the area of wear resistance. Foundation item: Project (50235030) supported by the National Natural Science Foundation of China; Project (51489020104JS9102) supported by the National Key Laboratory for Remanufacturing     

Machining process model based on virtual reality environment

Virtual manufacturing is fast becoming an affordable technology with wide-ranging applications in modern manufacturing. Its advantages over existing technology are primarily that users can visualize, feel involvement and interact with virtual representations of real world activities in real time. In this paper, a virtual cutting system is built which can simulate turning process, estimate tool wear and cutting force using artificial neural network etc. Using the simulated machining environment in virtual reality (VR), the user can practise and preview the operations for possible problems that might occur during implementation. This approach enables designers to evaluate and design feasible machining processes in a consistent manner as early as possible during the development process. Foundation item: Projects (50475117, 50175081) supported by the National Natural Science Foundation of China; project (033181611) supported by the Science and Technology Commission of Tianjin Municipal     

Influence of oxides on high velocity arc sprayed Fe-Al／Cr3C2 composite coatings

Fe-Al/Cr3C2 coatings were sprayed on low steel by high velocity arc spraying(HVAS) technology. The influences of oxides on erosion, corrosion and wear behavior for high velocity arc sprayed Fe-Al/Cr3C2 coatings were studied. The results show that HVAS-sprayed Fe-Al/Cr3C2 coatings have good erosion, heat corrosion and wear resistance. The erosion resistance improves with the increase of the temperature. On one hand, the ferrous oxides are incompact, so they peel off the surface of the coatings easily during the high temperature erosion. On the other hand, compact Al2O3 films on the surface can protect the coatings.     

Fatigue life prediction of crankshaft repaired by twin arc spraying

This paper used Baumel Jr. and Seeger’s approach estimating fatigue parameters of 48MnV with 3Cr13 coatings. The fatigue life of the crankshaft of a six-cylinder engine, repaired by twin arc spraying 3cr13 deposits, is respectively calculated using different damage model such as S-N method, normal strain approaches, SWT-Bannantine approaches, shear strain approaches, and fatemi-Socie method based on dynamical simulation and FE analysis of crankshaft. The results indicate that the traditional calculation is conservative and that the life of crankshaft repaired by arc spraying is sufficient. Foundation item: Project (50235030) supported by National Natural Science Foundation of China     

Wet friction performance of C/C-SiC composites prepared by new processing route

C/C-SiC composites with SiC island distribution were prepared via a new processing route. The fabrication process mainly included silicon infiltration by ultrasonic vibration, chemical vapor deposition (CVD), siliconizing, liquid phase impregnation and carbonization. The wear and friction properties were tested by an MM-1000 wet friction machine. The results show that SiC phases are mainly distributed between carbon fibers and pyrocarbons as well as among the pryocarbons. The dynamic friction coefficient of the composites decreases gradually from 0.126 to 0.088 with the increase of the surface pressure from 0.5 to 2.5 MPa at the same rotary speed. Furthermore, under the constant surface pressure, the dynamic friction coefficient increases from 0.114 to 0.126 with the increase of the rotary speed from 1 500 to 2 500 r/min. However, the coefficient decreases to 0.104 when the rotary speed exceeds 4 500 r/min. During the friction process, the friction coefficient of C/C-SiC composite is between 0.088 and 0.126, and the wear value is zero after 300 times brake testing. Foundation item: Project(2006CB600901) supported by the Major State Basic Research and Development Program of China; Project(0991015) supported by Guangxi Science Found, China; Project(200808MS083) supported by Guangxi Education Department Found     

Life cycle of remanufactured engines

The life cycle index of remanufactured engines was assessed by using the method of life cycle assessment (LCA). A remanufactured engine of a certain domestic brand was taken as researching object. Engine reproducing engineering was investigated from three aspects which were energy, material and environment. The application of LCA on remanufacturing engines was discussed in detail with a practical case. The results indicate that remanufacturing an engine can save 55 kg steels, 8.3 kg aluminum and 113 kW · h electric powers and reduce emissions of 565 kg CO₂, 6.09 kg CO, 1.01 kg NO _x , 3.985 kg SO _x and 288.725 kg solid waste. The remanufacturing of engines possesses great economic value and practicability. Foundation item: Project (50235030) supported by the National Natural Science Foundation of China     

Analysis of self-repair films on friction surface lubricated with nano-Cu additive

The surface modified nanocopper particles were prepared with chemical reduction method. The wear test was carried out on a T-11 ball-on-plate friction and wear tester made in Poland. The material of the upper sample was GCr15 and the counterpart was AISI-1045 steel. The morphologies of the worn surfaces of the samples were observed by optical microscope and scanning electron microscope, while the element distributions on the worn surfaces were determined by means of electron microprobe analysis. As the results, a film mainly made of Cu is formed on the worn surface. The film on the surface of the still upper sample is thicker than that formed on the revolving counterpart. At the edge of the groove of the worn surface made by the milling before test there is Cu element observed obviously, but there is not any Cu element in the bottom of the groove. A possible action mechanism of the film is suggested. The friction movement can induce reactivity of the metal and continuously produce activation surface. It benefits the film formed by nano-Cu in lubricant on the worn surface. Hardness and modulus of nano-Cu films were successfully measured and analyzed by the nanoindentation instrument. The results show that the hardness and modulus of the films are lower than those of the initial surface. Foundation item: Project (50235030) supported by the National Natural Science Foundation of China; Project (G1999065009) supported by the National Key Basic Research Special Foundation     

End-of-life vehicle recycling based on disassembly

The end-of-life vehicle recycling was studied based on the disassembly. The end-of-life recycling and the disassembly were reviewed and discussed. A disassembly experiment of an end-of-life engine was carried out, which strictly recorded the process of dismantling. Based on the results, a model of the end-of-life recycling was presented. In this model, the end-of-life parts were classified by three ways which included to recycle directly, to recycle after remanufacturing and to discard. By using this model, the dismantling efficiency and the recycling rate can be improved. Also, it obtains a good result after used in a dismantling factory. Foundation item: Key Project (50235030) supported by the National Natural Science Foundation of China     

Directly searching method for slip plane and its influential factors based on critical state of slope

In order to determine the slip plane of slope directly by the calculation results of strength reduction method, and analyze the influential factors of slope stability, a numerical model was established in plane strain mode by FLAC3D for homogeneous soil slope, whose parameters were reduced until the slope reached the critical state. Then FISH program was used to get the location data of slip plane from displacement contour lines. Furthermore, the method to determine multiple slip planes was also proposed by setting different heights of elastic areas. The influential factors for the stability were analyzed, including cohesion, internal friction angle, and tensile strength. The calculation results show that with the increase of cohesion, failure mode of slope changes from shallow slipping to the deep slipping, while inclination of slip plane becomes slower and slipping volume becomes larger; with the increase of friction angle, failure mode of slope changes from deep slipping to shallow slipping, while slip plane becomes steeper and upper border of slip plane comes closer to the vertex of slope; the safety factor increases little and slip plane goes far away from vertex of slope with the increase of tensile strength. Foundation item: Project(20060533071) supported by the Doctoral Program Foundation of Higher Education of China; Project (20060400264) supported by China Postdoctoral Science Foundation; Project (50774093) supported by the National Natural Science Foundation of China; Project (1343-74236000014) supported by Graduate Student Innovation Foundation of Hunan Province, China     

Influence of CYP3A5 polymorphism on tacrolimus blood concentrations in renal transplant patients

Objective Tacrolimus is an immunosuppressive drug with narrow therapeutic range and wide interindividual variation in its pharmacokinetics. Tacrolimus is a substrate of cytochrome P450(CYP)3A5. The aim of this study was to evaluate whether the A6986G polymorphism is associated with tacrolimus concentration /dose ratio. Methods Fifty-two Chinese renal transplant patients were enrolled in this study. Their body weight, dosage and concentration of tacrolimus were observed. CYP3A5 genotype was determined by polymerase chain reaction followed by restriction fragment length polymorphism analysis. Results A significant association was found between tacrolimus levels per dose/kg/d and CYP3A5 gene A6986G polymorphism (P<0.001). The CYP3A5 * 3 * 3 patients have a significantly higher tacrolimus level/dose than CYP3A5 * 1 * 1 and CYP3A5 * 1 * 3. Conclusions CYP3A5 gene A6986G polymorphism is associated with tacrolimus pharmacokinetics and dose requirements. Pharmacogenetic methods could be employed prospectively to help the dose selection and to individualize immunosuppressive therapy according to the result. Foundation item: Project (03GZ3072) supported by the Science and Technology Department of Hunan Province; project (2004035206) supported by the China Postdoctoral Foundation and project (30300383) supported by the National Natural Sciences Foundation of China     

Effect of infiltrating Si on friction properties of C/C composites

In order to improve the friction-wear properties of the C/C composites for aircraft brake pairs, the friction behavior of samples with infiltrating Si was investigated. The influence of Si smearing thickness on friction properties was studied in detail. The results show that with the increase of Si smearing thickness and β-SiC content, the friction coefficient reduces from 0. 40 to 0. 30; the linear wear of stators increases from 2. 0 μm to 18. 9 μm per cycle, and that of rotors increases from 1. 4μm to 22. 6 μm per cycle; mass wear of stators increases from 20. 6 mg to 126. 9 mg per cycle, and that of rotors increases from 13. 7 mg to 166. 2 mg per cycle. On the other hand, when a large number of inhomogeneous β-SiC particulates are performed, friction surfaces of the samples flake off layer by layer and many nicks are observed.     

Estimation of compaction grouting pressure in strain softening soils

A new method was proposed to predict the limited compaction grouting pressure for the soft soils. Theoretical basis of the method considered the conical shear failure above the grout bulb. Using the Mohr-Coulomb yield criterion as the initial yield function, the limited compaction grouting pressure was determined, according to the softening elastic-plastic model based on the conventional triaxial compression tests to simulate the strain softening soils. The small strain in the elastic zone and large stain in the plastic zone and the rational yield function for the strain softening phase stage, the analytical solutions to the compaction grouting pressure were presented. The results indicate reasonable agreement and show a good potential of the proposed method for rationally optimizing the design of compaction grouting operations. Foundation item: Project (200550) supported by the Foundation for the Author of National Excellent Doctoral Dissertation of China; Project (09JJ1008) supported by Hunan Provincial Natural Science Foundation of China     

Sand-wear resistance of brush electroplated nanocomposite coating in oil and its application to remanufacturing

Sand-wear resistance of nano scale alumina particle reinforced nickel matrix composite coating (n-Al₂O₃/Ni) prepared by brush electroplating technique was investigated via wear tests in sand-contaminated oil lubricant, comparing with that of AISI1045 steel and brush electroplated Ni coating. Effects of testing load, sand content and sand size on worn volume of the three materials, and also coating surface roughness on worn volume of the brush electroplated coatings were accessed. Results show that the worn volume of all the three materials increases with increasing of testing load, sand content and sand size. In the same conditions, n-Al₂O₃/Ni composite coating has the smallest worn volume while AISI1045 steel has the largest because of the n-Al₂O₃ particle effects. As to n-Al₂O₃/Ni and Ni coatings, the surface-polished coatings have obviously lower worn volume than the as-plated coatings. The brush electroplated n-Al₂O₃/Ni composite coating was employed to remanufacture the sand-worn bearing seats of a heavy vehicle and good results were gained. Foundation item: Project (50235030) supported by the National Natural Science Foundation of China; Project (51489020104ZD0401) supported by the National Key Laboratory for Remanufacturing; Project(51418060105JB3058) supported by National Defence Foundation     

Design of wear-out-failure in-situ repair parts by environment-friendly nanocopper additive

Oleic acid surface-modified Cu nanoparticles with an average size of 20 nm were prepared by liquid phase reducing reaction. The tribological performance and mechanism of nanocopper as additive were studied by means of tribotester, scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS) and nanoindentation instrument. The results indicate that the modified nanocopper additive can significantly improve the wear resistance and reduce friction coefficient of base oil. A copper protective film is formed and contributes to the excellent tribological properties of nanocopper additive. On the basis of the film forming mechanism, a new in-situ repair method was designed and used to repair wear-out-failure injection pump plunger and barrel. Furthermore, the current research progress of nanoparticles as green energy-saving lubricating oil additives were presented. Foundation item: Project (50235030) supported by the National Natural Science Foundation of China     

Feasibility study of marrow stromal cells transplantation into guinea pig cochlea

Objective This pilot-study was designed to evaluate the feasibility of cell transplantation into guinea pig cochlea. Methods Marrow stromal cells were labeled with DAPI, and then implanted into the cochlea of guinea pig. The existence and differentiation trend were observed roughly two weeks later by histologic analysis. Results Transplant-derived marrow stem cells survived in cochlea two weeks later with a trend of attaching to cochlear architecture but not differentiate into neuron. Conclusions Transplant-derived marrow stem cells can survive in cochlea, and cell transplantation may be a useful strategy in inner ear diseases. Foundation item: Project (30000094) supported by the National Nature Science Foundation of China; project supported by the Postdoctoral Foundation of Central South University