Plating Concentrate for Wear-Resistant Metal-Ceramic Film
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Solution Overview
Problem
Existing lubricating compositions for motor and industrial oils fail to provide stable, long-lasting anti-friction properties due to rapid oxidation and aggregation of metallic particles, leading to increased wear and friction coefficients in engine and gearbox components.
Innovation Solution
A plating concentrate comprising a powdered metal filler, surfactants, oil-soluble dialkyl dithiophosphoric acid metal salts, and a mineral filler based on silicates, along with cyclohexanol, forms a protective metal-ceramic film with high adhesion and wear resistance, reducing the friction coefficient to 0.03-0.07 and maintaining stability for extended periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If copper based alloy powder is used to form a protective film on friction surfaces, then wear resistance is improved, but the film is quickly worn after oil discharging and friction coefficient remains significant
Solution Approach 1:
The patent uses a composite powder mixture containing copper-based alloy particles (2-20% by weight) combined with ceramic particles (80-98% by weight) to form a protective film. This composite structure provides both the wear resistance of metal and the stability of ceramic, resolving the contradiction between wear resistance and film stability after oil discharging.
Solution Approach 2:
The patent changes the particle size parameters of the powder mixture to 0.01-10 μm and controls the copper content at 2-20% by weight. These parameter optimizations ensure proper film formation and adhesion while preventing excessive wear, addressing the reliability issue of quick film degradation.
2Object-affected harmful factors
If metallic particles are added to lubricating composition to reduce friction, then friction coefficient decreases, but particles oxidize and aggregate deteriorating lubricant quality
Solution Approach 1:
The patent introduces surfactants as intermediary substances that prevent direct contact and aggregation between metallic particles and the lubricant medium. The surfactants form a protective interface that prevents oxidation and aggregation of copper-based alloy particles, eliminating the harmful effects while maintaining low friction.
Solution Approach 2:
The patent creates an inert environment around metallic particles through the use of surfactants and ceramic matrices that protect copper-based alloy particles from oxidation. This protective environment prevents particle aggregation and maintains lubricant quality over extended periods.
3Object-affected harmful factors
If dialkyl dithiophosphoric acid metal salts are used to form protective film, then friction is reduced, but salts rapidly oxidize and lose anti-friction properties
Solution Approach 1:
The patent uses dialkyl dithiophosphoric acid metal salts as a temporary, sacrificial protective layer that forms quickly to reduce friction during running-in. These salts are designed to be consumed or transformed during operation, providing immediate friction reduction while being replaced by more stable ceramic-based protective structures.
Solution Approach 2:
The patent applies dialkyl dithiophosphoric acid metal salts as a preliminary treatment before the main protective film forms. These salts quickly deposit and provide immediate friction reduction during the initial running-in period, preparing the surface for subsequent stable protective film formation from ceramic and metal particle combinations.
4Stability of the object's composition
If succinimide additive is used as dispersant to maintain particles in suspended state, then particle dispersion is improved, but additive weakly interacts with metallic particles and does not exert desired effect
Solution Approach 1:
The patent changes the chemical parameters of the surfactant system by using fatty acids (C12-C22) with specific carbon chain lengths and ratios (5-30% by weight). These parameter optimizations enhance the interaction between surfactants and metallic particles, improving dispersion stability while maintaining strong particle-surfactant interactions.
Solution Approach 2:
The patent combines multiple surfactant components including fatty acids (C12-C22 mono-carbonic acid), zinc stearate, and copper stearate in specific ratios to create a composite surfactant system. This composite approach provides both dispersion stability and strong interaction with metallic particles, resolving the effectiveness issue.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The concentrate significantly reduces wear velocity and friction momentum, maintaining antifriction properties for over 500-600 cycles without reapplication, with a stable friction coefficient and enhanced heat removal, while preventing oil oxidation and particle aggregation.
Implementation Method 1
During a decomposition of dialkyl dithiophosphoric acid metal salts (Fe, Co, Ni, Al, Mo, Cu, Zn, Sn, Pb), the metals of the above-defined series are precipitated on the friction surfaces
Implementation Method 2
the metals of the above-defined series are precipitated on the friction surfaces
Implementation Method 3
surfactants—a fatty C12-C22 mono-carbonic acid and/or a salt thereof with copper (copper stearate) or with zinc (zinc stearate)
Implementation Method 4
a mineral filler based on silicates 1.2-20
Implementation Method 5
the friction coefficient after running in is not higher than 0.03-0.07
Data Source
AI summary
The object of the present invention is to provide a protective metal-ceramic film having a heterogeneous structure and possessing higher density, wear resistance, a high adhesion to a friction surface and a friction coefficient after running in not higher than 0.03-0.07.The above object is solved by providing a plating concentrate comprising a powdered metallic filler, surfactants, oil soluble dialkyl dithiophosphoric acid metal salts and a basic oil, a mineral filler based on silicates and cyclohexanol at the following ratio of components in % by weight:a powdered metallic filler0.05-20.0surfactants 0.5-11.0dialkyl dithiophosphoric acid metal salts 1.0-45.0a mineral filler based on silicates 1.2-20.0cyclohexanol0.05-2.0 A mineral filler based on silicates comprises natural minerals from a series of layered hydro silicates such as serpentinite and/or chlorite.Salts of zinc and/or tin and/or molybdenum and/or aluminum and/or copper and/or cadmium are used as dialkyl dithiophosphoric acid metal salts.