Application industries
The mineral coating technology applied in metallurgy allowed consumers to significantly reduce the cost of production, increase the reliability of metallurgical equipment operation, increase the overhaul period and reduce repair and downtime costs.
In December 2015, an agreement was signed with SMS Group GmbH (Germany), the world's leading manufacturer of metallurgical equipment, on joint efforts to improve the reliability of the Group's metallurgical equipment service life extension.
Coating working conditions:
- at high temperatures up to 1300 (degrees) C;
- at thermocyclic loads over a wide temperature range;
- in an atmosphere of abrasive dust from metal particles and high hardness abrasive;
- aggressive media of salt spray, hydrogen sulphide, water vapor, acids.
Also, the mineral coating technology:
- has no limitations in terms of mass and size characteristics;
- does not require special baths, furnaces, vacuum chambers and special conditions;
- does not change the geometry of the parts to be machined;
- is a finishing operation that does not require drawing changes;
- is an environmentally friendly technology that does not have a harmful impact on human health and the environment.
All these factors make it possible for the successful application of mineral coating technology in the metallurgical industry.
Using mineral coating technology we are ready to significantly increase the service life of parts operating in conditions of high temperature, acid, water vapor, metal abrasive dust, creating wear-resistant mineral coatings on parts of the pipe forming mill of different diameters, parts of the piercing mill, parts of the automatic mill, parts of the calibration mill (rollers, fittings, gears, shears).
The combination of physical processes of the technology makes it possible to increase the wear resistance of friction pair parts from 3 to 10 (up to 50 times) times compared to traditional methods, allows parts with mineral coating to work at temperatures and aggressive environment. The technology protects the parts of operating mechanical systems of any purpose against wear and tear, increases their life and reduces energy consumption by maximizing the elimination of mechanical losses in machines and mechanisms.
The essence of the technological process is the introduction of minerals of natural origin into the metal crystal lattice. The combination of ultradisperse mineral powders and an ultrasonic indenter results in the formation of a nanocomposite surface structure with fragments ordered in composition and dimension, and a controlled, depending on the purpose, change in the mechanical characteristics of the nanocomposite coating material and the main material of the component.
The technology of formation of a mineral coating consists in the process of applying a mineral layer on a surface of a part by means of ultrasonic unit, with simultaneous plastic deformation of surface layers by means of ball or roller knurls, and also the processes protected in a know-how mode. The use of pressing (pressure application) creates the effect of volume compression of the base metal and mineral in the plastic deformation zone, and, as a consequence, the hardening of the surface layer volume. The technology may include electric arc mass transfer of metal microparticles to create a hard-metal cushion.
As a result, nanostructured composites with predicted properties (antifriction, wear-resistant, anti-seize) are formed in the surface layer due to the reduction of the average size of crystallites and the compaction of the base material.
The basic technology serves as a basis for further development of routing and working technologies for different surfaces, parts of different weights and sizes for metallurgy and chemical engineering.
References:
- Kislov S.V., Kislov V.G., Balasch P.V., Skazochkin A.V., Bondarenko G.G. and Tikhonov A.N. Wear resistance of a metal surface modified with minerals / Materials Science and Engineering, / IOP Conf. Series: Materials Science and Engineering 110 (2016). Electronic access: [http://iopscience.iop.org/article/10.1088/1757-899X/110/1/012096/pdf]
- Kislov S.V., Kislov V.G., Skazochkin A.V., Bondarenko G.G., Tikhonov A.N. Efficient mineral coatings for surface hardening of metal materials / Metals, 2015, №4, pp.56-63.
- Balash P.V., Kislov S.V., Skasochkin A.V. Small innovative enterprise: opportunities for technology development and business scaling, journal «Innovations», 2015, № 12, pp.95-105.
by SPC Mineral Coating Technologies, LLC with grant support from the Skolkovo Fund.