DOI: 10.5937/jaes0-42291
This is an open access article distributed under the CC BY 4.0
Volume 21 article 1122 pages: 810-819
The development of new fields in the oil and gas industry of Kazakhstan, the exploitation of fields with hard-to-recover reserves, and the exclusion of harmful environmental impacts require the study of new advanced technologies in the manufacture of valves. Hardening of the throttle tip in the factory from low-carbon corrosion steel is provided traditionally: carburizing in a solid carburetor, followed by hardening and normalization in an electric furnace. However, this process is accompanied by high heat losses, long time spent on heating and cooling the furnace to the required temperature, and high-energy consumption - power costs are 60-100 kW/h. The carbon penetration rate is low, and for depths of 1-1.5 mm, it becomes necessary to heat the workpiece in a carburetor for 8-10 hours at a certain temperature, followed by hardening and normalization. The technological process of traditional hardening by cementation, followed by hardening and normalization, is accompanied by the appearance of various defects. The most common defects include the formation of microcracks, warpage, scale, and peeling of the metal, as well as high labor intensity and energy intensity.
A technology has been developed for hardening the tip on an electrolytic-plasma modification installation, which includes heating the part to 910-9600C and quenching in an electrolyte flow at 330-3600C, characterized in that the part is heated by electrolyte plasma, the temperature of which exceeds 6000 K. Analytically and experimentally it was determined that heating with electrolyte plasma for quenching is achieved within 4 seconds and quenching in the electrolyte flow is achieved within 8 seconds. With cyclic electrolytic plasma hardening at the 10th cycle with 40 seconds of total processing, optimal hardening rates are achieved.
An electron microscopic study of the hardened structure indicates a phase transformation and the formation of hardening martensite with a carbide network, which strengthens the steel. The tribological properties and friction coefficient of the surface layers formed during electrolytic-plasma hardening indicate an increase in the wear intensity by more than two times.
1. Kombayev, K., Muzdybayev, M., Muzdybayeva, A., Myrzabekova, D., Wieleba, W., & Leśniewski, T. (2022). Functional Surface Layer Strengthening and Wear Resistance Increasing of a Low Carbon Steel by Electrolytic-Plasma Processing. Strojniški vestnik-Journal of Mechanical Engineering, vol. 68(9), 542-551.
2. ASTM E1558-09(2014), Standard Guide for Electrolytic Polishing of Metallographic Specimens, ASTM International, West Conshohocken, PA, 2014, www.astm.org
3. Smyrnova, K., Sahul, M., Haršáni, M., Pogrebnjak, A., Ivashchenko, V., Beresnev, V., Vanco, L. (2022). Microstructure, Mechanical and Tribological Properties of Advanced Layered WN/MeN (Me= Zr, Cr, Mo, Nb) Nanocomposite Coatings. Nanomaterials, vol. 12, 395.
4. Pogrebnjak, A. D., Beresnev, V. M., Bondar, O. V., Postolnyi, B. O., Zaleski, K., Coy, E., & Araujo, J. P. (2018). Superhard CrN/MoN coatings with multilayer architecture. Materials & Design, vol. 153, 47-59.
5. Doudkin, M., Kombayev, K., Kim, A., Azamatov, B., Azamatova, Zh. (2020). Research of cutting temperature reducing of titanium alloy grade 5 below polymorphic transformation depending on calculation of cutting modes. International Journal of Mechanical and Production Engineering Research and Development (IJMPERD), vol. 10, issue 2, 747–758, https://doi.org/10.24247/ijmperdapr202074.
6. Mikhalev, A. D., Dyadyura, K. A., Lebedynskyi, I., Bratushka, S. N., & Kravchenko, Y. O. (2019). Structure, morphology, and elemental-phase composition of j02002 steel as a result of electrolytic-plasma processing. High Temperature Material Processes: An International Quarterly of High-Technology Plasma Processes, 23(1).
7. Kombayev, K. K., Doudkin, M. V., Kim, A. I., Mlynczak, M., Rakhadilov, B.K. (2019). Surface hardening of the aluminum alloys Al3 by electrolytic-plasma treatment. News Of the national academy of sciences of the republic of Kazakhstan. Series of geology and technical sciences, vol. 4, no. 436, 222 – 229, https://doi.org/10.32014/2019.2518-170X.117.
8. García-Leóna, R.A., Martínez-Trinidada, J., Campos-Silvaa, I., Figueroa-López U., Guevara-Morales B., A. (2021). Development of tribological maps on borided AISI 316L stainless steel under ball-on-flat wet sliding conditions. Tribology International, vol. 163, 107161, https://doi.org/10.1016/j.triboint.2021.107161.
9. García-Leóna, R.A., Martínez-Trinidada, J., Zepeda-Bautistaa, R., Campos-Silvaа, I., Guevara-Morales B, A., Martínez-Londoñoa, J., Barbosa-Saldaña, J. (2021). Dry sliding wear test on borided AISI 316L stainless steel under ball-on-flat configuration: A statistical analysis. Tribology International, 157, 106885, https://doi.org/10.1016/j.triboint.2021.106885.
10. Korzhyk, V., Tyurin, Yu., Kolisnichenko, O. (2021). Surface modification of metal products by electrolyte plasma. Kharkiv: РС ТЕСHNOLOGY СЕNTЕR 180.
11. Kozha, E., Smagulov, D.U., Akhmetova, G.E., Kombaev, K.K. (2017). Laboratory installation for electrolytic-plasma treatment of steel. NEWS of national academy of sciences of the republic of Kazakhstan, vol. 4(424), 219-225.
12. Steblyanko, V. L., & Ponomarev, A. P. (2016). Plasma-Electrolytic Treatment as an Innovative and Resource-Saving Technology of Metal Surface Treatment. In Materials Science Forum, vol. 870, 416-421.
13. Kombayev, K., Kim, A., Yelemanov, D., Sypainova, G. (2022). Strengthening of Low-Carbon Alloy Steel by Electrolytic-Plasma Hardening. International Review of Mechanical Engineering (I.RE.M.E.), vol. 16(2), 84–91. DOI: 10.15866/ireme.v16i2.21712
14. Popov, A. I., Radkevich, M. M., & Teplukhin, V. G. (2020). Thinnest finishing treatment with a focused jet of electrolytic plasma. In Advances in Mechanical Engineering, 139-149.
15. Ayday, A., Derya, K., Şükran Demirkıran, A. (2022). The Effects of overlapping in electrolytic plasma hardening on wear behavior of carbon steel. Transactions of the Indian Institute of Metals, vol. 75.1, 27-33.
16. Liang, J., Hossain, N. I., Wahab, M. A., & Guo, S. (2012). Improvement of Corrosion Resistance on a Low Carbon Steel 1018 in 3.5% NaCl Solution by Electrolytic-Plasma-Process (EPP). In ASME International Mechanical Engineering Congress and Exposition, vol. 45196, 821-825.
17. Dayanç, A., B. Karaca, and L. Kumruoğlu. (2017). The cathodic electrolytic plasma hardening of steel and cast iron based automotive camshafts. Acta Physica Polonica A, vol. 131.3, 374-378.
18. Popova, N. A., et al. (2020). Structure and Phase Composition of Ferriticperlitic Steel Surface after Electrolytic Plasma Quenching. Russian Physics Journal, vol. 63.5, 791-796.
19. Mikhalev, A. D., et al. (2019). Structure, morphology, and elemental-phase composition of j02002 steel as a result of electrolytic-plasma processing. High Temperature Material Processes: An International Quarterly of High-Technology Plasma Processes, vol. 23.1
20. Miller, D. J., Dreyer, D. R., Bielawski, C. W., Paul, D. R., & Freeman, B. D. (2017). Surface modification of water purification membranes. Angewandte Chemie International Edition, vol. 56(17), 4662-4711.
21. Zhang, F., et al. (2021). Effect of annealing temperature on microstructure and mechanical properties of plasma sprayed TiC-Ti5Si3-Ti3SiC2 composite coatings. Surface and Coatings Technology, vol. 422, 127581.
22. Wieleba, W. (2005). The role of internal friction in the process of energy dissipation during PTFE composite sliding against steel. Wear, vol. 258(5-6), 870-876.
23. Wieleba, W., (2007). The mechanism of tribological wear of thermoplastic materials. Archives of Civil and Mechanical Engineering, vol. 7(4), 185-199.
24. Rakhadilov, B. K., Buranich, V. V., Satbayeva, Z. A., Sagdoldina, Z. B., Kozhanova, R. S., Pogrebnjak, A. D. (2020). The cathodic electrolytic plasma hardening of the 20Cr2Ni4A chromium-nickel steel. Journal of Materials Research and Technology, vol. 9(4), 6969-6976. doi:10.1016/j.jmrt.2020.05.020.
25. Mazhyn, S., Bauyrzhan, R., Erlan, B., Michael, S. (2014). Change of structure and mechanical properties of R6M5 steel surface layer at electrolytic-plasma nitriding doi:10.4028/www.scientific.net/AMR.1040.753
26. Rakhadilov, B., Zhurerova, L., Pavlov, A. (2016). Method of electrolyte-plasma surface hardening of 65G and 20GL low-alloy steels samples. IOP Conference Series: Materials Science and Engineering, vol. 142(1) doi:10.1088/1757-899X/142/1/012028.
27. Rakhadilov, B. K., Kenesbekov, A. B., Sagdoldina, Z. B., Stepanova, O. A. (2020). Tribological And Corrosion Characteristics Of Coatings Based On Chromium Nitride Deposited By The Mechanochemical Method. Journal of Physics: Conference Series, vol. 1529, no. 4, 042101.
28. Kengesbekov, A., Rakhadilov, B., Sagdoldina, Z., Buitkenov, D., Dosymov, Y., Kylyshkanov, M. (2022). Improving the Efficiency of Air Plasma Spraying of Titanium Nitride Powder. Coatings, vol. 12(11), 1644.
29. Ptak, A., Taciak, P. and Wieleba, W., (2021). Effect of Temperature on the Tribological Properties of Selected Thermoplastic Materials Cooperating with Aluminium Alloy. Materials, vol. 14(23), 7318.
30. Pawlak, W., Wieleba, W. and Wróblewski, R. (2019). Research of tribological properties of polylactide (PLA) in the 3D printing process in comparison to the injection process. Tribologia.
31. Doudkin, M., Kim, A., Sakimov, M. (2019). Mathematical and experimental study of deformations of a steel roll of a road roller with a variable geometry of a contact surface. Production Engineering Archives, vol. 25, 1-7. https://doi.org/10.30657/pea.2019.25.01
32. Doudkin, M., Kim, A., Młyńczak, M., Kustarev, G., Kim, V. (2019). Development and parameter justification of vibroscreen feed elements. Mining Machines and Earth-Moving Equipment: Problems of Design, Research and Maintenance, 203–226.
33. Doudkin, M., Kim, A., Savelyev, A., Zhileikin, A., Gribb, V., Mikhailovskaya, V. (2020). Modernization of the Metal Structure of the Grader Working Equipment. International Review of Mechanical Engineering (I.RE.M.E.), vol. 14, no. 1, 1-8
34. Vavilov, A., Kim, A., Guryanov, G., Likunov, A. (2020). New technology of the steel fiber manufacturing from technogenic waste. International Journal of Mechanical and Production Engineering Research and Development, vol. 10(3), 611–622.