AP14871373 "Development of supersonic arc metallization technology for restoration of worn surfaces of crankshafts of internal combustion engines"

Supervisor: Olga Stepanova, Candidate of Technical Sciences, Associate Professor

Relevance:

The crankshaft is one of the expensive parts of the engine, largely determining its resource. During the operation of the engine, the rubbing parts of the shaft wear out, and fatigue damage accumulates in the most dangerous areas, resulting in a decrease in its strength and, in particular, resistance to fatigue loads. The development of new progressive technological processes for the restoration of crankshafts of internal combustion engines, as well as the improvement of existing methods that ensure a given engine life by creating wear-resistant coatings on the surfaces of their root and connecting rod necks, high economic efficiency of the engine, is currently an urgent task.

Target:

Development of technology for restoring crankshafts of internal combustion engines by creating wear-resistant coatings based on iron by supersonic arc metallization on the surfaces of their root and connecting rod necks, as well as studying the patterns of formation of the structure and properties of iron-based coatings during supersonic arc metallization.

Expectation:

1. The structural-phase states and tribological properties of iron-based coatings obtained by supersonic arc metallization will be investigated.

2. The regularities of the formation of the structure and properties of iron-based coatings during supersonic arc metallization will be studied.

3. As a result of the project, new data will be obtained on the relationship of the structure with the tribological properties of iron-based coatings obtained by supersonic arc metallization.

4. The technological process of restoration of worn surfaces of crankshafts of internal combustion engines by supersonic arc metallization will be developed.

5. A site for the repair and restoration of crankshafts of internal combustion engines will be created.

Result:

Experiments on obtaining a coating on grade 45 steel with a surfacing wire made of grade 30KhGSA steel were carried out on a laboratory setup made for electric arc metallization, consisting of a current source, a compressor and an EM-14M metallizer at the Scientific and Research Center for Surface Engineering and Tribology and the Scientific Center for Surface Modification of Materials. Experiments were conducted to determine the optimal parameters for spraying by electric arc metallization, such as: wire feed speed, distance to the substrate sample, voltage and pressure of the pumping air. The obtained samples were tested for wear resistance using the ball-on-disk scheme on a TRB3 tribometer (S. Amanzholov Higher School of Engineering). The microhardness of steel samples was measured on an HLV-1DT device, with indenter loads of P = 0.2 N and a holding time of 10 sec under this load. Coating adhesion strength tests by the pull-off method were conducted on an Elcometer 510 adhesion meter (S. Amanzholov Higher School of Engineering). Coating abrasive wear tests were conducted according to GOST 23.208-79. The tests were conducted using a rubber wheel and dry sand. Sand is fed between the rotating wheel and the test sample. The wheel is pressed against the sample, and the abrasive, getting into the gap, wears out the test sample. Sample wear is assessed by the change in the weight of the test sample. A metallographic microscope HL-102AW was used to study the general nature of the structure. Also, images of the sample surface and cross-section were taken using a JSM-6390 LV scanning electron microscope (SEM) from JEOL (Japan) with an INCA ENERGY 250 X-ray spectral microanalysis system from OXFORD INSTRUMENTS to measure the coating thickness and determine the coating porosity. The experimental results showed that the best coating results can be obtained in the electric arc metallization mode on the above-mentioned installation for 30KhGSA surfacing wire: the distance to the target is 16 cm, the voltage supplied to the surfacing wire is 35 V, the current is 200 A, the atmospheric pressure is 0.8 MPa and the wire feed speed is 4 cm/sec. The resulting layer when sprayed in this mode with a thickness of 450 μm had a hardness of HV = 350 and was much better in porosity than other samples. Also, according to the calendar plan, work was performed to create a crankshaft holder manipulator for supersonic electric arc metallization of its journals. The installation allows fixing the crankshaft between the front and rear headstocks with a spindle, mounted on a linear axis and performing a rotating movement of the processed shaft. The maximum distance between the headstocks is 1450 mm. The metallizer is installed on a fixation unit, which allows changing the distance and angle of spraying. The headstock is driven by a gearbox. Stepper motors of the 57BYG250C-8 model serve as a power element. The speed of rotation of the crankshaft and movement along the horizontal axis of the metallizer are carried out by digital control based on the ATmega16 microcontroller. Optimum grinding modes for restored crankshaft journals have been determined. The use of a coolant significantly reduced the thermal impact on the coating during grinding, preventing the occurrence of cracks and oxidative changes, thereby preserving the original phase composition and mechanical properties of the coatings. A study of the effect of grinding on the structure of the coatings showed that changing the parameters of the grinding process did not lead to significant structural changes. This contributed to maintaining the stability of the crystalline structure of alpha iron and FeO. The emulsion provided excellent heat removal and effective cleaning of the working surface from grinding waste, which contributed to the creation of a more even and smooth coating, reduced roughness and ensured the strength of the adhesion of the coating to the substrate without visible deterioration. To assess the service life of restored crankshafts, a rig for accelerated testing of crankshafts for wear will be developed and manufactured. The developed rig for accelerated testing of crankshafts simulates engine operating conditions. The rig is equipped with a frame with mechanisms for fastening and precise positioning of the shaft, and the load on the shaft is supplied through electric motors with the ability to adjust the speed and angle of rotation. Shaft testing includes vibration and wear measurements to evaluate its performance and wear resistance under various conditions.

2023


  • А. Б., Рахадилов, Б. К., Степанова, О. А., Кусаинов, Р. К., Жасулан, А. Ж., & Даумова, Г. К. (2023). INVESTIGATION OF THE PROCESS OF ELECTRIC ARC METALIZATION OF COATINGS FROM STEEL 30KhGSA. Eurasian Physical Technical Journal, 20(4 (46)), 67-73. https://doi.org/10.31489/2023No4/67-73

2024


  • Рахадилов, Б. К., Шынарбек, А. Б., Какимжанов, Д. Н., & Степанова, О. А. (2024). ВЛИЯНИЕ СКОРОСТИ ПОДАЧИ ПРОВОЛОКИ СВЕРХДУГОВОЙ МЕТАЛЛИЗАЦИИ НА СТРУКТУРУ И КОРРОЗИОННЫЕ СВОЙСТВА ПОКРЫТИЙ ИЗ СТАЛИ 30ХГСА. Вестник НЯЦ РК, (2), 43-49. DOI: https://doi.org/10.12913/22998624/190251
  • Rakhadilov, B., Shynarbek, A., Kakimzhanov,D., Kusainov, R., Zhassulan, A., & Ormanbekov, K. (2024). Effect of Voltage on Properties of 30HGSA Steel Coatings by Supersonic Arc Metallization Method. Advances in Science and Technology ResearchJournal, 18(5), 113-124. http://www.astrj.com/Effect-of-Voltage-on-Properti..

Study Team Members

  • Fullname: Рахадилов Бауыржан Корабаевич, PhD

    Scopus Id: 55539741700

    Researcher Id: ---

    ORCID: 0000-0001-5990-7123

    Additionally: