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Antifriction silumin as a substitute of antifriction bronzes
Summary
Antifriction silumin (AS) is a new, relatively light and wear-resistant alloy on basis of aluminum with high mechanical and antifriction properties. The frictional wear resistance of AS is not worse than that of the most widespread Al-Fe and Pb-Zn-Sn bronzes such as БрАЖ9-4, БрОЦС5-5-5, etc., and can substitute them in friction units (worm wheels, sleeve bearings, bushings). Cost and mass of AS billets are less than those of bronze ones by a factor of 2.5.
Description
AS billets are made by the higher solidification rate casting method. This method makes it possible to obtain billets in diameters up to 200 mm with the superfine microstructure without application of modifying addition alloys and fluxes. Subsequent special rapid heat treatment improves tribotechnical properties of AS billets. These billets have the inverted microstructure with globular silicon crystals measuring 2÷4 microns. Mechanical properties of worm and toothed wheels made of AS are not worse than those of the bronze ones and their antifriction properties exceed analogous of the latter 4 - 6 fold. AS solid and hollow billets are made by continuous-horizontal, iterative and centrifugal casting methods. These production methods are relatively simple, efficient and do not require introduction of expensive alloying elements. The Institute of Technology of Metals can produce the following AS billets:[br][/br]- solid cut-to-length cylindrical billets in diameters up to 200 mm and heights up to 150 mm;[br][/br]- hollow billets with outer diameters from 90 to 200 mm;[br][/br] -continuously cast bars with diameters from 40 to 80 mm.[br][/br]
Technology Type
Material
Technology Benefits
Technical parameters of antifriction silumin billets:[br][/br] - hardness - 125÷140 НВ;[br][/br] - tensile strength - 350÷450 MPa;[br][/br] - elongation - 4÷8 %;[br][/br] - density - 2700 kg/m3.[br][/br][br][/br]Technical parameters БрАЖ 9-4 Antifriction silumin[br][/br]Material's density, kg/m3 7500 2700[br][/br]Comparative wear resistance 1 4÷6[br][/br]Mass of a billet (Ø100mm, length 100 mm), kg 5.9 2.2[br][/br]Cost of 1 kg (VAT included), $ USD 10 12[br][/br]Cost of a billet (Ø100mm, length 100 mm), $ USD 59 26.4[br][/br][br][/br]Mechanical properties of AS billets are not worse than those of the bronze ones and their antifriction properties exceed analogous of the latter 4 - 6 fold. Cost and mass of AS billets are less than those of Al-Fe and Pb-Zn-Sn bronze billets by factors of 2÷2.5 and 2.5÷3, respectively.[br][/br]
Technology Differentiation and Uniqueness
An innovative aspect is the method of casting of Al-Si alloys with 4÷6-μm globular silicon crystals uniformly distributed in the aluminum matrix without application of modifying agents, which has developed in the SSI «ITM of NAS of Belarus». Due to this microscopic structure, mechanical and antifriction properties of AS billets obtained exceed those of Al-Fe and Pb-Zn-Sn bronze billets.
Context in which technology was identified
Hanover international industrial exhibition on April 08 - 12, 2013, Hanover, Germany[br][/br]XX International exhibition congress "High technologies. Innovations. Investments" (HI-TECH’2014) on March 12-14, 2014, St. Petersburg[br][/br]5th Harbin international exhibition of scientific and technical achievements on June-6 27 July, 2014, Harbin, People's Republic of China[br][/br]Ural international industrial exhibition of "INNOPROM-2014" on July 09-12, 2014, Yekaterinburg[br][/br]To the 6th International specialized exhibition "World of Metal-2014", (on September 16-18, 2014), Minsk.[br][/br]22nd International scientific and technical conference and exhibition "Foundry production and metallurgy 2014. Belarus" Minsk, on October 22-24, 2014.[br][/br]Now worm wheels and bearings of sliding from antifrictional alpax are successfully introduced and replace bronze at the following enterprises of Republic of Belarus: JSC Belshina (Bobruisk), JSC Bobruyskselmash (Bobruisk), JSC Stankozavod Krasny Borets (Orsha), JSC Optik Plant (. Lead), state of emergency "VS-Tekhnika" (Polotsk), ChUP "Transmaster" (Mogilev) and state of emergency of "Novaeks Plus" (Mogilev), etc.
Technological Keywords
Antifriction silumin, antifriction bronzes, friction, wear resistance, microstructure, accelerated cooling, Charpy principle.
Development Stage
Currently in use/production
Intellectual Property Rights
Patent
Specific Patent Information (Patent Number, Country, Patent Status)
Obtained decisions of granting titles of protection for subjects of industrial property:[br][/br]1. Invention а20111530 of 16.05.2013, Aluminum-Based Antifriction Alloy. V.Ju. Stetsenko, E.I. Marukovich, A.I. Rivkin [br][/br]2. Invention 2012119330 (RU) of 16.08.2013, Aluminum-Based Antifriction Alloy. V.Ju. Stetsenko, E.I. Marukovich.[br][/br]
Range of Applications
Engineering industry, machine-tool industry, repair service using worm wheels, toothed wheels, bearing shells, and guide bushes.
Classifier Used at the Enterprise Europe Network
Materials
Preferable Regions
South America
Europe
Asia
Practical Experience
AS worm wheels have successfully passed factory testing in surface-grinding machines at the RUPP "Stankozavod "Krasny Borets"» (Orsha). Basing on the testing results, AS worm wheels are recommended for substitution of Pb-Zn-Sn bronze ones. AS worm wheels have successfully passed factory testing instead of Al-Fe bronze worm wheels in gearboxes of grinding-and-polishing machines at OAO "Zavod "Optik (Lida). [br][/br]Service life of AS worm wheels is 4-6 fold higher than that of Al-Fe bronze ones. AS sleeve bearings have successfully passed factory testing as substitutes of Pb-Zn-Sn bronze bearings in sliding couples of builders at OAO "Belshina" (Bobruisk). It has been shown that for 6 months of operation linear wear of AS bushings does not exceed 0.04 % that is better than for Pb-Zn-Sn bronze ones. There were no traces of wear and scars on mating sections of steel shafts.[br][/br]AS billets are now introduced into production and delivered at following enterprises of the Republic of Belarus : OAO "Belshina" (Bobruisk), OAO "Bobruiskselmash" (Bobruisk), OAO "Stankozavod "Krasny Borets" (Orsha), OAO "Zavod "Optik" (Lida), PO "Gomselmash" (Gomel), ChP "VS-Technika" (Polotsk), ChUP "Transmaster" (Mogilev) and ChP «Novaeks Plus» (Mogilev), etc.[br][/br]
Environmental Impact
AS worm wheels have successfully passed factory testing in surface-grinding machines at the RUPP "Stankozavod "Krasny Borets"» (Orsha). Basing on the testing results, AS worm wheels are recommended for substitution of Pb-Zn-Sn bronze ones. AS worm wheels have successfully passed factory testing instead of Al-Fe bronze worm wheels in gearboxes of grinding-and-polishing machines at OAO "Zavod "Optik (Lida). [br][/br][br][/br]Service life of AS worm wheels is 4-6 fold higher than that of Al-Fe bronze ones. AS sleeve bearings have successfully passed factory testing as substitutes of Pb-Zn-Sn bronze bearings in sliding couples of builders at OAO "Belshina" (Bobruisk). It has been shown that for 6 months of operation linear wear of AS bushings does not exceed 0.04 % that is better than for Pb-Zn-Sn bronze ones. There were no traces of wear and scars on mating sections of steel shafts.[br][/br]AS billets are now introduced into production and delivered at following enterprises of the Republic of Belarus : OAO "Belshina" (Bobruisk), OAO "Bobruiskselmash" (Bobruisk), OAO "Stankozavod "Krasny Borets" (Orsha), OAO "Zavod "Optik" (Lida), PO "Gomselmash" (Gomel), ChP "VS-Technika" (Polotsk), ChUP "Transmaster" (Mogilev) and ChP «Novaeks Plus» (Mogilev), etc.[br][/br]
Type of Collaboration Sought
For Sale
Terms&Restrictions
By arrangement
Available Technical Assistance
Documentation
Personnel
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