Method of working surfaces of units and assemblies of thermal engines

IPC classes for russian patent Method of working surfaces of units and assemblies of thermal engines (RU 2253696):

C23C26 - Coating not provided for in groups ; C23C0002000000-C23C0024000000

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FIELD: thermal engines.

SUBSTANCE: method comprises supplying preliminary prepared fluid into the working zone. The fluid comprises hydrocarbon agent, preliminary disintegrated mineral powder, and catalyzer. The mineral powder is made of an activated basalt of 5 μm dispersity. The catalyzer is made of alcohols.

EFFECT: enhanced reliability and efficiency.

2 ex

The invention relates to heat engines, in particular to methods for integrated surface treatment of components and assemblies of heat engines.

Heat engines are widely used in transportation, energy, engineering, agriculture and life.

Therefore, at present has developed various ways to restore the working surfaces of components and assemblies of the engine by preventing fatigue of metals corrosion strength work surfaces, improved anti-friction properties, which lead to the extension of engine life, reduce energy consumption and consumption of fuels, improve the environment by reducing harmful emissions and noise.

The known method is capable of restoring the operational parameters of the friction pairs (patent RF №2199609, MKI 23 With 26/00, 23 P 6/00, 2001), including the preliminary preparation of the repair composition, the flow of the composition in the friction zone, the formation of surface friction in the areas of maximum stress and intensive wear of ceramic coatings in the standard mode of operation. The repair composition contains a base oil and a powder with a particle size of not more than 40 μm, obtained artificially from industrially produced chemicals. OS is low powder is amorphous silicon dioxide in combination with magnesium silicates, ferrosilicate, aluminosilicates and the catalyst in the following ratio, wt.%:

Amorphous silica 20-70

Magnesium silicates 10-50

Ferrosilicate 5-25

The aluminosilicates 2-15

The catalyst for the Rest

And the powder is up to 30 wt.% the repair part and the base oil - the rest.

As catalyst, use of industrially produced modification of carbon or a mixture of industrially produced modifications of carbon: graphite and black carbon. The amount of catalyst is chosen from 0.01%.

The disadvantages of the known method is capable of restoring the operational parameters of the friction pairs are:

- is not able to assess the working condition of the site without disassembly of the latter;

- the need for individual selection of the quantitative components of the powder and catalyst for each engine.

The closest in technical essence and the achieved result to the claimed solution is the modification of iron-containing surfaces of friction (RF patent No. 2201999, MKI 23 With 24/02, 26/00//, 23 P 6/02, 2001). How is that in the treatment area of the friction surfaces serving pre-cooked technological environment containing hydrocarbon media and 0.008-0.03 wt.% pre-shredded mix mi is the Eraly α -chrysotile, arthristis, lizardite tape, dolomite, catalyst and surface active substances (surfactants) in the following ratio in their mixture, wt.%:

αChrysotile 25-35

Arthritis 35-45

Lizardite tape 5-15

Dolomite 5-15

The catalyst 2-5

Surfactants 5-8

The dispersion of particles of mineral components and the catalyst is 0.1 to 4.0 μm. As the catalyst used, the oxides of rare earth metals, platinum or mixtures thereof, and as the surfactant is sodium atomistically, or sodium bicarbonate, or Nickel nitrate.

Modification of friction known method allows to increase the durability of the rubbing metal surfaces.

However, the known method has a number of disadvantages.

The high complexity of the technological process of selection of mineral raw materials ultrabasic rocks.

The need for enrichment of minerals by purification from impurities, including wash in water α-chrysotile and orchrestra, processing them 20%acetic acid, lizardite tape washed and treated with hydrochloric acid at a temperature of 95°and after enrichment them dried and conduct magnetic separation.

In addition, in the known method it is necessary to grind each component to the dispersion of 0.1 to 4.0 μm, and then to mix them. The mixture is of the composition of the individual dispersed materials requires special equipment.

The task of the invention is to improve the reliability of operation of heat engines by increasing efficiency, reducing consumption of fuel and lubricants and increase turnaround, reducing the load on the environment and increase engine compression.

To solve the problem in the known method, including flow in the treatment area of the friction surfaces pre-cooked technological environment containing hydrocarbon media, pre-crushed mineral powder and a catalyst, as a mineral powder used activated basalt with particle size up to 5 μm, and the catalyst - alcohols.

Because activated basalt has high energy properties, the introduction of a mixture of basalt and catalyst, allows the free ions of the metals of the mixture to penetrate into the base metal, forming on the surface troostite structure, composition close to that of perlite having high strength and ductility. This leads to the restoration of the working surfaces of components and assemblies, including bearings, to prevent metal fatigue, uvelichenie corrosion resistance, cohesive strength work surfaces, improved anti-friction properties. Resulting increases with the OK maintenance-free operation of the engine, reduced energy consumption and the consumption of fuel and lubricants, environmental improvement by reducing harmful emissions and noise.

The method is as follows.

thermal engine is considered as a system with more than 90 percent of mobile interfaces exposed to friction and shock, in which when the work flow of mechanochemical processes with the release of energy and the emergence of tribalism. The composition prepared from the powder of activated basalt with high energy properties, and alcohol catalyst, is injected inside the heat engine. With the introduction of the composition to the inside of the heat engine and started running through the cooling system and lubrication composition is delivered to all the friction components. Zone pair of nodes into zones of active introduction of free metal ions from the composition of the base metal, forming troostite structure, composition close to that of perlite having high strength and ductility. Presence in areas of friction high pressure (crank mechanism) tribalism allows you to get and also the surface layer of the metal close to the factory default settings of friction. In addition, the presence tribalism in the coupling zone of the piston - liner creates a sufficiently high potential thermo is DS, and at the time of the outbreak of the working mixture, at a pressure of 3.5 to 5.0 MPa and a temperature of 2200~2500°occurs diffraction thermopower, resulting in tribalism in the area of the upper piston part and increase compression, regardless of the state of the system of rings (compression and oil).

Examples of implementation of the method.

Example 1.

The engine of the car “UAZ-452” 1995 release that is installed on the ambulance, operated in elevated mode. The compression ratio in the engine cylinders were: first - 0,88; the second is 3.5; in the third - 3,2; the fourth is 2.8. The compression ratio was measured by the technical staff using standard compressometer with a multiplier of 0.5 kg/cm². The engine was introduced the composition from a mixture of powder activated basalt and alcohol catalyst based on 1 g of the powder and 10 g of catalyst per 1 liter of the working oil. After 15 minutes of operation of the engine compression ratio cylinders made: in the first - 3,8; the second - 4,0; in the third - 4,0; in the fourth and 3.8.

After 500 kilometers in the cylinders of the engine was measured by the compression ratio, which amounted to: in the first - 6,0; the second 6,0; in the third - 6,0; in the fourth to 6.0. After leaching, the replacement of oil and oil filter and repeated treatment with the compound in the same proportions. After 15 minutes of operation, the compression ratio in the engine cylinders were: first - 7,0; what about the second 7,0; in the third - 7,0; in the fourth of 7.0. After 5000 miles the car was put on the repair. The engine is disassembled and inspected. It is established that the inner surface of the engine cleaned of sludge, in areas of friction (crankshaft, camshafts) detected the presence of films of high hardness of gray. The measurements showed that the parameters of the nodes close to the specifications of the manufacturer.

Example 2.

Buses “Ikarus”, 1981 edition. The engine is operated in the high coolant temperature (more than 95° (C)was observed gas leaking into the cooling system, increased smoke emissions when the engine is running, the noise agregate transmission when driving and switching speeds. The compression ratio measured in the cylinders of the engine had the following figures: in the first 26 kgf/cm²; in the second, 27 kgf/cm²; in the third of 25 kgf/cm²; in the fourth - 26 kgf/cm²; in the fifth - 25 kgf/cm²; in the sixth - 25 kgf/cm². The bus was prepared for the repair, engine replacement connecting rod and piston, as well as preventive maintenance of units. In consultation with management, it was decided to conduct a comprehensive processing engine, and units with a mixture of powder activated basalt and alcohol catalyst. The mixture of the powder of basalt dispersion is up to 5 μm in a quantity of 1 g of the catalyst in an amount of 10 g per 1 liter of the technological environment was introduced into the liquid cooling system of the engine. It is noted that over 100 kilometers, the temperature of the engine has decreased to a standard operational value (80°). Re-processing of the cooling system was carried out according to the same scheme over 500 kilometers of bus. After another 500 km of marked cessation of gas leaking into the cooling system of the engine. Was a complete replacement of coolant flushing the engine cooling system. In the wash water was observed in the presence of a large number of particles of limescale.

In the next step, the mixture of powder and catalyst in a similar proportion was introduced through the mouth directly into the engine in the old working oil. The engine has been started and worked in normal mode. After 500 kilometers measuring the compression in the cylinders of the engine was re-done and showed that the compression ratio amounted to: in the first 29 kgf/cm²; second - 30 kgf/cm²; in the third 29 - kgf/cm²; in the fourth - 29 kgf/cm²; in the fifth - 28 kgf/cm²; in the sixth - 29 kgf/cm². From the engine was removed oil, in which the high content of particles of sludge and friction products. The engine was washed with wash solution was replaced oil and oil filter. Then in the engine with new oil was introduced a mixture of powder and catalyst scheme, similar to the first treatment. The bus was put into operation.

In the third stage of complex treatment has been the treatment of gears, bearings mounted equipment and bearings of naves of the wheels of the bus. In working technological environment through water holes was introduced a mixture of powder and catalyst in the amount of 0.02 wt.%. After 200 kilometers noise in the gearbox and rear axle transmission ceased. Decreased emissions of CO₂and SN, fuel consumption decreased by 18%. Over 5000 kilometers the bus was set to validate the results of processing. Technical test results showed that:

1. The cooling system is completely free of limescale.

2. The inner surface and the nodes of the engine, the grooves of the pistons, oil scraper rings, gas distribution mechanism (working surfaces of the valves cleaned of soot, the tightness of the gaskets was restored.

3. All moving parts of the engine purified from foods sludge oil, cervical crankshaft and camshafts restored to operational parameters and are coated gray.

4. Technical rubber products retained their operational characteristics.

5. Gear, gearbox, rear axle, bearings, slides, and bearings of the wheels restored to operational parameters. Backlash carton transfer did not exceed 12°and the backlash of the rear axle not previs the l 60° (the inspection was conducted by the unit K-428).

6. Revision of units and aggregates of motor and transmission have shown that as a result of complex processing units and assemblies of the engine and powertrain their condition close to or corresponding to the operational parameters. This allows us to conclude that the invention allows to carry out preventive maintenance of components and assemblies of the heat engine without disassembly. After the audit, inspection, change of lubrication, the engine was assembled and put into operation. Next oil change carried out through 90000 km with the obligatory introduction to the technological environment of the engine of powder mixtures of basalt and alcohol catalyst in a concentration of 0.001 wt.%. As a result of processing the bus is running in economy mode, noise and emissions are minimized.

These examples show that the use of the proposed technical solutions provided by the restoration of the basic operational parameters of the components and assemblies of heat engines, improved anti-friction performance, reduced energy losses.

Method for surface treatment of components and assemblies of heat engines, including flow in the treatment area of the friction surfaces pre-cooked technological environment containing hydrocarbon is of the l, pre-crushed mineral powder and a catalyst, characterized in that as a mineral powder used activated basalt with particle size up to 5 μm, and the catalyst - alcohols.