XADO revitalization technology
Revitalization is the formation of a metal-ceramic coating on the friction surfaces of an operating unit when XADO revitalizant gel is added in stages to the standard oil.
Coating formation mechanism
Under overloads, excess energy directed at destroying the surfaces is released at the local contact points of friction pairs. When revitalizant is present in the friction zone, conditions arise in the overloaded areas under which a new coating forms on the surface instead of the existing one being destroyed.
The “metal — metal” friction pair is replaced by a “metal-ceramic — metal-ceramic” pair; the coating forms on the crystal lattice of the surface layer of parts made of any metals and their alloys. The process runs during normal operation, without disassembly of the component and without taking the unit out of service.
Coating characteristics according to instruction IE-24.6-25612000-005-2008: microhardness up to 750 kg/mm², roughness down to Ra 0.06 µm. The coating formation diagram is given on revitalizant.com in the “Technology” section.
General provisions of the XADO technology →Process conditions
- Stage-by-stage addition of the calculated quantity of gel to the standard oil with the prescribed running time between stages; the consumption rate and the number of stages are set by the component method;
- allowance for oil losses when an individual method is developed: leaks and burn-off consumption above 0.5 % per hour of the oil bath volume or above 0.4 % of fuel consumption — a recommendation of the general provisions of the instruction.
Measured and unmeasured parameters
The effect of the technology on a component is assessed by instrumental measurements before and after treatment with the same instrument in the same mode.
Measured in test reports
- compression by cylinder;
- vibration acceleration and vibration velocity;
- noise level;
- drive current and power consumption;
- oil and working fluid pressure;
- radial clearances and axial play of bearings;
- tooth thickness;
- time for the compressor to reach operating pressure;
- roughness and ovality of a test workpiece turned on the machine tool;
- roughness of the ring raceways of bearing 60314 after 80 h of running-in on a test bench — Ra 0.0673–0.0745 µm along the rolling track versus 0.1343–0.1474 µm outside the track (UK EPK JSC);
- roughness of the disc of a “steel — cast iron” friction pair after 304 h on an MI friction machine — Ra 1.2 → 0.08–0.1, in the control test without revitalizant — Ra 1.1 → 0.25–0.3 (Kharkiv Tractor Plant);
- fuel and oil consumption.
Not measured
- component service life to failure: test reports record the running time without repair as of the report date; the factor of service life increase is given only in the general provisions of the instruction;
- thickness, microhardness, composition and structure of the coating: their control requires laboratory conditions. Strengthening of friction surfaces is recorded in two cases of the catalogue: by measurement of cylinder wall hardness, 269–278 → 292–347 HB (KT-6 compressors, Stoilensky GOK), and by inspection during a control disassembly (ZB-360Pm gearbox, Nikolaev Alumina Refinery CJSC).
Industrial audit and pilot testing by XADO — at our expense
XADO Zero-Cost Pilot