Project: Duplex Treatments for Ultra Load Capacity Bearings
Bearings are a critical element in the operation of rotatory elements. Nowadays are used in all sectors and in some of them have a critical role. There are some kinds of bearings, depending on the rotatory element, geometry or material._x000D__x000D_The most used material in the manufacture of bearings is carbon steel (1%) with 1.5% of chromium. Most of the six million tons of bearing steel manufactured annually worldwide uses this composition. The alloy is referred to by numerous national and international designations (such as AISI 52100, 100Cr6, SUJ-2, 1.3505 …)_x000D__x000D_The properties of this steel provide good performance to bearings, and, in many cases, is enough to meet the requirements demanded. However, the use of conventional bearings can produce problems during bearing operation due to fatigue. This problems lead to an increment in the coefficient of friction and operating temperature, occurrence of undesirable vibrations, and finally can produce critical failure in the rotatory elements._x000D__x000D_It is estimated that 40% of world demand includes manufactures of heavy industrial machines, where mechanical requirements are too high for conventional bearings, and durability is a very important factor._x000D_There are sectors, as aeronautical, power generation or mining, where problems during operation, and its consequences, are not assumable. In these sectors conventional bearings are not an efficient solution, and special bearings are needed._x000D__x000D_It is estimated that 4% of the global market in bearing manufacture, that means 10000M€, is dedicated to special bearings. In many cases the current special bearings are not good enough, and customers need a solution to fatigue and durability problems._x000D__x000D_This project has the CO objective of producing a new kind of Ultra Load Capacity Bearing, which will be used where current special bearings are not good enough. This bearing will be manufacture using 100Cr6 steel, but the use of advanced duplex treatments will provide drastic enhanced fatigue resistance and durability._x000D__x000D_These duplex treatments will combine laser peening processes, thermochemical treatments and the deposition of PVD and Sol-Gel coatings. Advanced treatments will bring to the obtention of a new product able to solve the problems in many special current applications._x000D_The major impediment to obtaining this new product will be the appropriate combination of the manufacture process and the application of treatments. This impediment is due to the very precise manufacture tolerances that bearings need to ensure its proper operation. Nevertheless, expertize of the consortium and the knowledge gathered during project execution will be used to overcome these potential problems._x000D__x000D_It is important to remark that, to achieve all the objectives of this project, the consortium gathers the expertise of four entities with a very wide knowledge. The leader company, FERSA INNOVA, is a Spanish R&D-performing SME specialized in the analysis and improvement of bearings. This company was recently created by FERSA BEARINGS with the aim of concentrate its R&D, quality and engineering resources. Thereby, FERSA INNOVA has the know-how of a 50 years old company that has participated in several R&D projects._x000D__x000D_The second P of the consortium is Tratamientos Térmicos Carreras (TTC). This Spanish SME works in thermo-chemical treatments and advanced coatings since 1949. In the last decade the company has worked in many R&D projects related to PVD and CVD treatments, and also with thermo-chemical treatments._x000D__x000D_The third one is The Process and Engineering in Mechanics and Materials Laboratory (PIMM), a French research center expert in laser peening processes and advanced methods for numerical simulation to deal with the calculation of residual stresses induced by the process, and the resulting consequences on the service properties via the induced defects and microstructural modifications._x000D__x000D_The last P but not least is RESCOLL that is an R&D Performing SME focused on innovative technology. Its competences are related to industrial application in polymeric materials: resins, composites, adhesives and so on. Furthermore this center has a wide knowledge about surface treatments, as Sol-Gel, fatigue and failure analysise. RESCOLL has more than 15 years of experience in innovative projects and has already collaborated with a lot of international Ps._x000D_
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Acronym
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ULC BEARINGS
(Reference Number: 8323)
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Duration
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01/01/2014 - 31/12/2016
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Project Topic
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The project ULC BEARINGS is aimed to develop new processes based on duplex treatments combining Laser peening processes, thermo-chemical treatments and the deposition of PVD and Sol-Gel coatings to get Ultra Load Capacity Bearings
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Network
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Eurostars
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Call
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Eurostars Cut-Off 10
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Project partner
