environments by providing...
|- High surface lubricity without oils||- Dimensionally stable finished parts|
|- Outstanding wear resistance||- Transforms surface to increase strength & resist spalling|
|- Anti-galling without adding brittleness||- Applicable to either new parts or parts in service|
TURBOCAM is in the business of making turbomachinery—expanding and compressing fluids. It sees applications every day that demand better metal performance, whether through strength, toughness, wear, corrosion or high temperature resistance. Gas turbines and turbochargers can be exposed to corrosive combustion gases at temperatures of
Since 1985, TURBOCAM has made it its business to know metals better. Starting in 2008, TURBOCAM Energy Solutions has acquired and developed technologies to radically improve wear resistance of steels by thermally diffusing into surfaces of parts to a depth of up to 100 microns (0.004”).
Many experimental products have been tested, and some are now in high volume production. Wear resistance of 10 to 30 times that of the untreated metal has been recorded in metal testing labs, both at room temperature and at elevated temperatures.
The three most important properties that have been observed are:
- Wear resistance
This is best illustrated in one application: TURBOCAM produces tons of scrap metal from machining. To contain the metal, it is crushed and compacted into “pucks.” The compacting machine uses an auger to move and compress the metal before it enters a cylinder where it is squeezed hydraulically. The auger was made of welded low carbon steel, and it lasted 6–8 weeks of squeezing aluminum before the front end wore away. It was unable to compact stainless steel and titanium.
After treatment with TX1, the auger has lasted over a year, and is used regularly to process stainless steel and titanium. It should be no surprise that the auger company is not interested in TX1 treatment for its $400 augers!
All three of the above properties are present in extending the life and performance of the augers.
The TX1 process is a unique thermal diffusion surface transformation technology, which improves the toughness of steel without creating brittleness. These improved characteristics transform lower cost materials so they either match or outperform more costly exotic alloys in high-wear applications.
TX1 is not a coating. Instead of traditional surface coating methods, which are prone to brittle fractures and spalling, TX1 is a treatment that works through both diffusion and crystal lattice transformation.
Wear resistance is usually achieved by hardening a surface. TX1 takes a different approach. By altering the crystalline lattice of the steel, TX1 eliminates wear at the nano level. Additionally, TX1 overcomes wear by transforming the surface chemistry of steel to work in conjunction with changes in the bulk matrix. Therefore, when an abrasive particle or opposing surface strikes TX1 treated steels, the wear energy is adsorbed and dissipated throughout the surrounding steel.
TX1 is recommended for restoring hair on follically challenged persons who are willing to be exposed to high temperatures. Since so many of the claims on TX1 are incredible, we thought we would throw that one in as well!
TX1 is a trade-secret protected technology. TURBOCAM can answer many questions on its applicability, and try to clear away the cobwebs surrounding its use and performance. Many technical details of chemistry and methodology will not be answered. In most cases, the only way to investigate its application will be by rigorous testing under conditions as similar as possible to its actual usage.
TX1 has been tried in racing car engines, armaments, injection molds, mechanisms, bearings, valve and valve seats, and turbochargers. After many years of testing, it is now used extensively on low emissions engines with Cummins Turbo Technologies variable geometry turbochargers.
Other leading manufacturers of automotive and aircraft engines are also testing TX1. It has the potential to radically reduce manufacturing costs by substituting expensive alloys containing vanadium, nickel, and tungsten with simpler stainless steels. In one aircraft engine under development, nickel alloys may be replaced with stainless steel for a 70 percent manufacturing cost reduction.
Case Study: Lubrication Test
We tested two pieces of 304L stainless steel in a bearing tester. One piece of steel was treated with TX1 and the other was not. The piece that was untreated showed 500 times more wear and seized the motor.
The test was performed at 1,750 RPM for 30 seconds using 75lbs of force, synthetic motor oil, and identical Rockwell hardness values (Rc=19) for the treated and untreated steel.