Preparation method of graphene-containing metal wear self-repairing material for transmission lubricating system

Abstract

The invention discloses a preparation method of a graphene-containing metal wear self-repairing material for a transmission lubrication system, and relates to the technical field of industrial equipment lubrication and wear repair. The material is prepared from the following components in percentage by weight: 60 to 65 percent of mineral base material, 20 to 35 percent of nano reinforced phase, 5 to 10 percent of metal catalyst, 3 to 5 percent of dispersing agent and 1 to 3 percent of stabilizer. The material can automatically trigger in-situ reaction in the equipment operation process, a superhard, super-smooth and wear-resistant metal ceramic coating is formed on the surface of a friction pair, online repair of equipment abrasion is achieved, the fatigue resistance and wear resistance of a transmission part are improved, the service life of equipment is prolonged, and the operation and maintenance cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of industrial equipment lubrication and wear repair technology, specifically to a method for preparing a graphene-containing self-repairing metal wear material for transmission lubrication systems. Background Technology

[0002] Wear and tear on industrial equipment is the core factor leading to unplanned downtime, accounting for over 80% of all failures. This problem is particularly prominent in the wind power sector. Three major challenges for the wind power industry: 1. High operation and maintenance costs: The cost of a single inspection exceeds 20,000 yuan; the cost of hoisting a large gearbox is close to 600,000 yuan. 2. Difficulty in fault prediction: The failure rate of bearing microcracks is as high as 83%, and 37% of gearbox burn-out accidents are due to alarm delays. 3. High safety risks: Maintenance requires working at heights, posing extremely high personal safety hazards.

[0003] Three core pain points of gearboxes: Gear failures accounted for 35%, ranking first among all failures; more than 50% of gear failures were caused by electrical erosion and pitting; electrical erosion originated from stray current discharge, forming 1–5 μm arc pits on the tooth surface. Pitting corrosion, on the other hand, causes surface peeling due to cyclical changes in contact stress, eventually leading to tooth breakage.

[0004] Traditional repair methods rely on disassembly, welding, or replacement, requiring downtime of 15–30 days and resulting in significant power generation losses (approximately 10,000 RMB per unit per day). Therefore, developing intelligent self-healing technology that can be implemented online without downtime has become an urgent need for the industry.

[0005] In recent years, metal self-healing technology has emerged, utilizing frictional heat to trigger in-situ reactions and generate a dense metal-ceramic coating on worn surfaces, thus transforming passive maintenance into active protection. However, existing products still have limitations in terms of dispersion stability, reaction sensitivity, and resistance to extreme environments, making it difficult to meet the requirements of complex working conditions such as high-temperature salt spray at sea and low-temperature conditions at high altitudes. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the present invention aims to provide a method for preparing a graphene-containing self-healing metal wear material for transmission lubrication systems. This material can automatically trigger an in-situ reaction during equipment operation, forming an ultra-hard, ultra-slippery, and wear-resistant metal-ceramic coating on the surface of the friction pair, thereby achieving online repair of equipment wear, improving the fatigue resistance and wear resistance of transmission components, extending equipment life, and reducing operation and maintenance costs.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solution: a graphene-containing self-repairing metal wear material for transmission lubrication systems, comprising the following components by weight percentage: 60-65% mineral matrix, 20-35% nano-reinforcing phase, 5-10% metal catalyst, 3-5% dispersant, and 1-3% stabilizer.

[0008] Preferably, the mineral substrate is magnesium hydroxysilicate (Mg6[Si4O3]2O3). 10 [OH]8), with a particle size of 1.0-3.0 μm, serves as a matrix material for metal-ceramic coatings, providing high-temperature reactivity; Preferably, the nano-reinforcing phase is graphene with a particle size of 15-60 nm, which improves thermal conductivity and shear resistance.

[0009] Preferably, the metal catalyst is one or more of nano copper powder, nickel powder or cobalt powder, with a particle size of 50-100nm, to promote metallurgical bonding. Preferably, the dispersant is a modified polyetheramine, polyethylene glycol (PEG), or oleic acid to ensure that the material is uniformly suspended in the lubricating oil.

[0010] Preferably, the stabilizer is a silane coupling agent or epoxy resin to enhance the compatibility of the material with the lubricating oil.

[0011] A method for preparing a graphene-containing self-healing metal wear material for a transmission lubrication system includes the following steps: 1. Ball mill magnesium hydroxysilicate to a particle size of 0.3-3.0 μm; calcine it in a muffle furnace at 300-500℃ for 2-4 hours to remove surface moisture and impurities, retaining the active hydroxyl groups to obtain a highly active matrix material; 2. Commercially available aminated graphene is used and dried for later use; 3. Mix the aminated graphene with nano-metal particles (Cu / Ni / Co) at a mass ratio of 3:1; grind the mixture for 2-4 hours under argon protection using a high-energy ball mill to obtain a uniform composite powder; control the particle size of the particles after grinding to 50-100 nm (monitored in real time using a laser particle size analyzer). 4. Mix the calcined magnesium hydroxysilicate with the composite powder (graphene + metal catalyst) at a mass ratio of 6.5-7:3.5-3, add dispersant and stabilizer, and stir in a high-speed mixer at 2000-3000 rpm for 1-2 hours to ensure uniform mixing of materials; place the mixture in an oven at 80-100℃ and dry for 4-6 hours to obtain self-healing composite material powder.

[0012] 5. Mix the composite material powder with the base lubricating oil (such as PAO-10) at a mass ratio of 1.7:10; use ultrasonic dispersion technology, control the temperature in an ice-water bath (≤40℃), and disperse for 30-60 minutes (avoid local overheating that could lead to graphene agglomeration or lubricating oil oxidation); filter with a 300-mesh filter and then encapsulate to obtain the finished self-healing lubricating oil.

[0013] 6. Vacuum degassing treatment, vacuum degree ≤ -0.09MPa, time 25-35 minutes, to remove air bubbles; dispensing into nitrogen-protected sealed containers to avoid oxidation; adding to the transmission lubrication system at a ratio of 1-3% during use to achieve online wear repair.

[0014] Preferably, the commercially available aminated graphene is grafted with -NH2 and has a purity of ≥99%.

[0015] Preferably, the ultrasonic dispersion technology has a power of 500W and a frequency of 20-40kHz.

[0016] The beneficial effects of this invention are as follows: Through material innovation, process optimization, and intelligent repair mechanism, this invention can repair electrical corrosion and pitting defects online, with a repair area ratio of ≥90%, forming a metal-ceramic coating with a thickness of 3–5 μm and a hardness of ≥HV800. The friction coefficient is reduced by more than 30%, and the transmission efficiency is improved by 5–8%. It achieves non-stop operation, no disassembly, and no long-term downtime losses. It has significant advantages such as long service life, superior performance, low energy consumption, and strong environmental protection, and has broad application prospects and social value. Detailed Implementation

[0017] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0018] The specific embodiment adopts the following technical solution: a graphene-containing metal wear self-repairing material for transmission lubrication system, which is composed of the following components by weight percentage: mineral matrix 60-65%, nano-reinforcing phase 20-35%, metal catalyst 5-10%, dispersant 3-5%, and stabilizer 1-3%.

[0019] It is worth noting that the mineral substrate is magnesium hydroxysilicate (Mg6[Si4O3]2O4). 10 [OH]8), with a particle size of 1.0-3.0 μm, serves as a matrix material for metal-ceramic coatings, providing high-temperature reactivity.

[0020] It is worth noting that the nano-reinforcing phase is graphene with a particle size of 15-60 nm, which improves thermal conductivity and shear resistance.

[0021] It is worth noting that the metal catalyst is one or more of nano-copper powder, nickel powder or cobalt powder, with a particle size of 50-100nm, which promotes metallurgical bonding.

[0022] It is worth noting that the dispersant used is modified polyetheramine, polyethylene glycol (PEG) or oleic acid, to ensure that the material is uniformly suspended in the lubricating oil.

[0023] In addition, the stabilizer is a silane coupling agent or epoxy resin, which enhances the compatibility of the material with the lubricating oil.

[0024] A method for preparing a graphene-containing self-healing metal wear material for a transmission lubrication system includes the following steps: 1. Ball mill magnesium hydroxysilicate to a particle size of 0.3-3.0 μm; calcine it in a muffle furnace at 300-500℃ for 2-4 hours to remove surface moisture and impurities, retaining the active hydroxyl groups to obtain a highly active matrix material; 2. Commercially available amino-based graphene (surface grafted with -NH2, purity ≥99%) was used and dried for later use; 3. Mix the aminated graphene with nano-metal particles (Cu / Ni / Co) at a mass ratio of 3:1; grind the mixture for 2-4 hours under argon protection using a high-energy ball mill to obtain a uniform composite powder; control the particle size of the particles after grinding to 50-100 nm (monitored in real time by a laser particle size analyzer). 4. Mix the calcined magnesium hydroxysilicate with the composite powder (graphene + metal catalyst) at a mass ratio of 6.5-7:3.5-3, add dispersant and stabilizer, and stir in a high-speed mixer at 2000-3000 rpm for 1-2 hours to ensure uniform mixing; place the mixture in an oven at 80-100℃ and dry for 4-6 hours to obtain the self-healing composite material powder. 5. Mix the composite material powder with the base lubricating oil (such as PAO-10) at a mass ratio of 1.7:10; use ultrasonic dispersion technology (power 500W, frequency 20-40kHz), temperature controlled by ice water bath (≤40℃), and disperse for 30-60 minutes (avoid local overheating that may cause graphene agglomeration or lubricating oil oxidation); filter (300 mesh filter) and encapsulate to obtain the finished self-healing lubricating oil; 6. Vacuum degassing treatment (vacuum degree ≤ -0.09MPa, time 30 minutes) to remove air bubbles; dispensing into nitrogen-protected sealed containers to prevent oxidation; adding to the transmission lubrication system at a ratio of 1-3% during use to achieve online wear repair.

[0025] This specific embodiment discloses a method for preparing a graphene-containing self-healing metal wear material for a transmission lubrication system. This method effectively solves problems such as temperature rise, vibration, and excessive energy consumption caused by wear in industrial equipment, offering significant advantages including maintenance-free operation, extended lifespan, optimized performance, and energy conservation and environmental protection. This technology has been successfully applied in multiple industries such as wind power, hydropower, and chemical engineering, demonstrating promising industrialization prospects and significant potential for widespread adoption.

[0026] Example 1: This example provides a graphene-containing self-healing material for transmission lubrication systems, which is composed of the following components by weight percentage: 63% magnesium hydroxysilicate, 25% amino graphene, 6% nano cobalt powder, 4% oleic acid, and 2% epoxy resin.

[0027] The preparation steps are as follows: 1. Pretreatment of mineral substrate: Magnesium hydroxysilicate is ball-milled to an average particle size of 2.5 μm; it is then calcined in a muffle furnace at 400 °C for 3 hours to remove moisture and retain hydroxyl activity.

[0028] 2. Nanomaterial composite: Take commercially available amino graphene (purity 99.2%), dry it for later use; mix graphene and nano copper powder at a mass ratio of 3:1, and grind it for 3 hours under argon protection using high-energy ball milling to obtain composite powder with a particle size of 70nm.

[0029] 3. Preparation of composite materials: Calcined magnesium silicate and composite powder were mixed at a mass ratio of 6.8:3.2; modified polyetheramine and epoxy resin were added, and the mixture was stirred at high speed (2500 rpm) for 1.5 hours; the mixture was dried in an oven at 90℃ for 5 hours to obtain uniform powder.

[0030] 4. Lubricating oil preparation: Mix the powder with PAO 10 base oil at a ratio of 1.7:10; ultrasonically disperse (40kHz, 500W) for 45 minutes, controlling the temperature ≤40℃; filter and encapsulate, vacuum degassing treatment (-0.09MPa, 30 minutes); nitrogen protection for dispensing, the self-healing material content in the finished oil is 9%.

[0031] Application Test Case: Severe electrolytic erosion pits (1–5μm) appeared at the drive end of the gearbox of a 1.5MW unit in a wind farm in Chengde. After applying this material, the unit ran continuously for 90 days, and the results were as follows: Endoscopic examination showed that the electrolytic erosion area repair rate reached 92%, the oil temperature dropped by 8℃, the vibration value dropped by 22%, the load limit was lifted, and the unit resumed full-load operation without any downtime for maintenance. The stability of the equipment operation was significantly improved.

[0032] Example 2: This example provides a graphene-containing self-healing material for transmission lubrication systems, which is composed of the following components by weight percentage: 60% magnesium hydroxysilicate, 30% amino graphene, 5% nano nickel powder, 3.5% polyethylene glycol (PEG), and 1.5% silane coupling agent.

[0033] The preparation method differs from that in Example 1 in that the graphene content is increased to 30% to enhance thermal conductivity and lubrication performance; PEG is used as a dispersant, and silane coupling agent is used to improve compatibility with lubricating oil; the ball milling time is extended to 4 hours to ensure uniform dispersion of nanomaterials; and the ultrasonic dispersion time is increased to 60 minutes to avoid agglomeration.

[0034] Application test case: Pitting corrosion in the main bearings of multiple units at the Dashiya Wind Farm in Ye County caused excessive temperature rise. After using the above-mentioned repair materials, the units operated continuously for 60 days, and the results were as follows: the bearing temperature decreased by 6.5℃; the vibration acceleration decreased by 28%; the oil test showed that the iron content decreased by 62%; the bearings operated smoothly without any abnormal noise or oil leakage.

[0035] Example 3: This example provides a graphene-containing self-healing material for transmission lubrication systems, which is composed of the following components by weight percentage: 63% magnesium hydroxysilicate, 25% amino graphene, 6% nano cobalt powder, 4% oleic acid, and 2% epoxy resin.

[0036] The preparation method differs from that in Example 1 in that industrial-grade graphene (purity ≥95%) is used to reduce costs; oleic acid is used as a dispersant, which is suitable for neutral or weakly acidic lubricating oils; cobalt powder is selected as the metal catalyst to promote high-temperature reaction activity; and the drying temperature is controlled at 80°C to prevent oleic acid from volatilizing.

[0037] Application test example: rotary kiln support roller bearing in a cement plant, with an operating cycle of 45 days; the results are as follows: bearing temperature decreased by 5℃; average daily energy consumption decreased by 4.2%; bearing noise was significantly reduced and lubrication improved; cost was reduced by about 18% compared to the standard formula, making it suitable for economical maintenance scenarios.

[0038] Example 4: This example provides a graphene-containing self-healing material for transmission lubrication systems, which is composed of the following components by weight percentage: 60% magnesium hydroxysilicate, 22% amino graphene, 10% nano copper / nickel mixed powder, 5% modified polyetheramine, and 3% epoxy resin.

[0039] The preparation method differs from Example 1 in that the content of the metal catalyst is increased to 10%, enhancing catalytic activity and metallurgical bonding; copper-nickel mixed powder is used to improve high-temperature oxidation resistance; the ultrasonic dispersion power is increased to 600W to ensure uniform distribution of nanoparticles; and the addition amount is 3%, making it suitable for heavy-duty gearboxes, rolling mills, and other equipment.

[0040] Application test example: Blast furnace blower gearbox in a steel plant, with an operating cycle of 90 days, the results are as follows: oil temperature decreased by 10℃, gearbox vibration decreased by 35%, equipment operating efficiency increased by 4.5%, overhaul cycle was extended by 1.5 times, and maintenance costs were significantly reduced.

[0041] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A graphene-containing self-healing material for metal wear in a transmission lubrication system, characterized in that, It is composed of the following components by weight percentage: mineral matrix 60-65%, nano-reinforcing phase 20-35%, metal catalyst 5-10%, dispersant 3-5%, and stabilizer 1-3%.

2. The graphene-containing self-healing metal wear material for a transmission lubrication system according to claim 1, characterized in that, The mineral substrate is magnesium hydroxysilicate with a particle size of 1.0-3.0 μm.

3. The graphene-containing self-healing material for transmission lubrication systems according to claim 1, characterized in that, The nano-reinforcing phase is graphene with a particle size of 15-60 nm.

4. The graphene-containing self-healing material for transmission lubrication systems according to claim 1, characterized in that, The metal catalyst is one or more of nano-copper powder, nickel powder or cobalt powder, with a particle size of 50-100 nm.

5. A graphene-containing self-healing material for transmission lubrication systems according to claim 1, characterized in that, The dispersant used is modified polyetheramine, polyethylene glycol, or oleic acid.

6. The graphene-containing self-healing material for transmission lubrication systems according to claim 1, characterized in that, The stabilizer is a silane coupling agent or an epoxy resin.

7. A method for preparing a graphene-containing self-healing metal wear material for a transmission lubrication system, characterized in that, Includes the following steps: (1) Grind magnesium hydroxysilicate to a particle size of 0.3-3.0 μm; calcine it in a muffle furnace at 300-500℃ for 2-4 hours to remove surface moisture and impurities, retain the active hydroxyl groups, and obtain a highly active matrix material; (2) Commercially available amino-based graphene was used and dried for later use; (3) Mix the amino-based graphene with nano-metal particles at a mass ratio of 3:1; grind the powder for 2-4 hours under argon protection using a high-energy ball milling method to obtain a uniform composite powder; control the particle size of the particles after grinding to 50-100nm. (4) The calcined magnesium hydroxysilicate, composite powder graphene, and metal catalyst are mixed at a mass ratio of 6.5-7:3.5-3. Dispersant and stabilizer are added, and the mixture is stirred in a high-speed mixer at 2000-3000 rpm for 1-2 hours to ensure uniform mixing. The mixture is then dried in an oven at 80-100℃ for 4-6 hours to obtain self-healing composite powder. (5) Mix the composite material powder with the base lubricating oil at a mass ratio of 1.7:10; use ultrasonic dispersion technology, control the temperature in an ice-water bath to ≤40℃, and disperse for 30-60 minutes; filter with a 300-mesh filter and then encapsulate to obtain the finished self-healing lubricating oil; (6) Vacuum degassing treatment, vacuum degree ≤ -0.09MPa, time 25-35 minutes, to remove air bubbles; dispensing into nitrogen-protected sealed containers to avoid oxidation; adding to the transmission lubrication system at a ratio of 1-3% during use to achieve online wear repair.

8. The method for preparing a graphene-containing self-repairing metal wear material for a transmission lubrication system according to claim 7, characterized in that, The commercially available aminated graphene is surface-grafted with -NH2 and has a purity of ≥99%.

9. A method for preparing a graphene-containing self-repairing metal wear material for a transmission lubrication system according to claim 7, characterized in that, The ultrasonic dispersion technology described herein has a power of 500W and a frequency of 20-40kHz.