In the relentless pursuit of enhancing the durability and performance of heavy-duty equipment, a team of researchers led by ZHANG Peng from the State Grid Corporation Limited Extra High Voltage Construction Branch has made a significant breakthrough. Their work, published in the journal *Cailiao Baohu* (which translates to *Materials Protection*), focuses on improving the wear resistance of heavy-load wear plates used in cranes, particularly in high-altitude oil-water environments.
Diamond-like carbon (DLC) coatings have long been prized for their high hardness and low friction coefficients, making them ideal for protecting the surfaces of heavy-duty wear plates. However, these coatings often face challenges in extreme conditions, such as adhesion failure and reduced wear resistance when exposed to oil or water media under heavy loads. This limitation has been a persistent hurdle in the energy sector, where cranes operate in demanding environments.
The research team addressed this issue by employing a nitriding treatment to modulate the tribological properties of DLC coatings. By preparing nitrided DLC (N-DLC) coatings under various treatment conditions, they were able to significantly enhance the coatings’ load-bearing capacity. “The nitriding treatment has been a game-changer,” said ZHANG Peng. “It not only improves the hardness of the coatings but also promotes the formation of a lubricant film, which is crucial for reducing wear and friction.”
The team conducted extensive tests using a ball-on-disc tribometer under different conditions—dry friction, water lubrication, and oil lubrication—with loads ranging from 10 to 30 N. The results were impressive. The N-DLC coatings exhibited a remarkable reduction in friction coefficients and wear rates. Under oil lubrication, the friction coefficient decreased by 28.57%, and the wear rate dropped by an average of 40.20%. In water lubrication, the friction coefficient was reduced by 33.33%, with a 49.38% decrease in wear rate.
These improvements are not just academic; they have significant commercial implications for the energy sector. Cranes used in high-altitude and oil-water environments are subjected to extreme wear and tear, leading to frequent maintenance and downtime. The enhanced durability of N-DLC coatings means longer service life for wear plates, reducing maintenance costs and increasing operational efficiency.
The wear scar morphology analysis revealed a shift in the wear mechanism from severe abrasive wear to mild adhesive wear. This shift is primarily attributed to the increased hardness of the coatings due to the nitriding treatment and the synergistic effects of lubricant film formation. “This research provides a robust solution for the long-term protection of crane wear-resistant plates under complex service conditions,” added ZHANG Peng.
The findings published in *Cailiao Baohu* offer a promising avenue for future developments in the field of surface protection and tribology. As the energy sector continues to demand more from its heavy-duty equipment, innovations like N-DLC coatings will play a crucial role in meeting these challenges. The research not only enhances the performance of existing equipment but also paves the way for new applications in other industries where wear resistance is critical.
In an industry where every fraction of efficiency counts, this breakthrough could be a significant step forward, ensuring that cranes and other heavy-duty equipment operate more reliably and cost-effectively in some of the most demanding environments.