In the relentless pursuit of enhancing industrial components’ longevity and efficiency, a team of researchers from Ningbo University, Wenzhou University, and industry partners have made a significant breakthrough. Led by XIAO Jialin, the group has developed a novel epoxy resin (EP) coating infused with Ti3AlC2 and B4C, designed to bolster the performance of copper alloy bearing bushes in harsh methanol fuel leakage environments. This innovation, published in ‘Cailiao Baohu’ (translated to ‘Materials Protection’), holds promising implications for the energy sector, particularly in applications involving methanol fuel.
The research, a collaborative effort between academia and industry, addresses a critical challenge in the energy sector: the degradation of components due to corrosion and wear in aggressive environments. The team’s solution is an EP coating that not only enhances corrosion resistance but also improves tribological properties under varying temperatures.
The study’s lead author, XIAO Jialin, explained the significance of their work, “In environments where methanol fuel leakage is a concern, traditional coatings fall short in providing adequate protection. Our Ti3AlC2- and B4C-filled EP coating offers a robust solution, ensuring enhanced durability and performance of copper alloy bearing bushes.”
The researchers employed a liquid spraying method to apply the composite coating onto CuPb24Sn surfaces. They then subjected the coated samples to a formic acid and methanol mixed solution to evaluate corrosion resistance using electrochemical impedance spectroscopy. The results were impressive, with the composite coating exhibiting excellent corrosion resistance.
To assess the coating’s tribological performance under complex working conditions, the team conducted high-frequency reciprocating friction-wear tests in a formic acid, methanol, and lubricating oil mixture. The findings revealed that as the temperature increased, the coating’s friction coefficient decreased, while its wear rate increased. At 75°C, the wear scar was notably wider than at 25°C, with evident ploughing effects observed on the worn surface.
The team utilized Materials Studio software to simulate and calculate the underlying mechanisms. They discovered that the decrease in shear strength of the epoxy resin with increasing temperature was the primary factor influencing the coating’s wear rate.
This research opens up new avenues for developing advanced coatings tailored to withstand extreme conditions. As the energy sector continues to explore alternative fuels like methanol, the demand for robust, high-performance materials will only grow. This innovation could pave the way for more reliable and efficient components, reducing maintenance costs and downtime in industrial applications.
The implications of this research extend beyond the energy sector, with potential applications in automotive, aerospace, and marine industries, where components often face aggressive environments. As XIAO Jialin noted, “Our findings provide a foundation for future developments in coating technologies, driving innovation in various industrial sectors.”
With the publication of this study in ‘Materials Protection’, the research team has taken a significant step towards addressing the challenges posed by harsh operating environments. As the energy sector evolves, so too will the materials and technologies that support it, and this breakthrough is a testament to the power of interdisciplinary collaboration in driving progress.