One of our mill's transmission gearboxes is experiencing micropitting and heavy wear, indicated by high iron particulates found in the oil analysis. Unfortunately, we currently do not have the budget for a new set of gears. However, we are exploring alternative options to prolong the lifespan of the gears. At last year's Reliability Show, we came across a new metal treatment that can be applied on-site to restore the surface of gears, though the name escapes me at the moment. Any recommendations on how to address this issue would be greatly valued.
I also attended the Conexo, Inc. conference featuring the innovative Rewitec Surface Treatment. For more information, reach out to Ricardo Hein at 678-806-0131.
Thank you for reaching out! I was able to locate the website for Rewitec (www.rewitec.us) and found a case study that closely resembles my own situation. This is the product that stood out to me during the conference.
Thank you, Don, for the referral. Carlos is currently helping us address the micropitting issue. Since last year's trade show, we have seen significant advancements in various industries and applications. Visit our website at rewitec.us to see some of the results. In today's tough economic times, we are providing a solution for wear problems through a surface treatment that can enhance the load carrying capacity and prolong the lifespan of gears for many years. This treatment can be applied while the machine is in operation, minimizing downtime and improving surface properties such as wear resistance, abrasion resistance, oxidation resistance, wetability, adhesion, and fatigue strength. Would you like to improve the performance of your mechanical equipment by restoring worn metal surfaces, allowing them to handle higher loads, speeds, and temperatures? Let's discuss the potential benefits at the upcoming forum.
Is Metal Spray Coating Worth It? Uncover the Benefits and Advantages
Hey there, I have limited knowledge on this topic, but I am pretty sure that it is not a metal spray. Based on what I recall, this product is added to the lubricating oil and circulated through the system. It works to coat the gears during operation. Although I have not personally tried it yet, the website showcases some examples of its results. Is anyone in this forum familiar with this product?
I think the on-site application you're referring to might be a process called 'Laser peening'. It's a surface engineering process used to improve the mechanical performance of metals. It helps to increase hardness and resistance to various conditions, like wear, fatigue stress, and corrosion. Moreover, check out some advanced lubricants specifically designed for heavy-duty applications. These high-performance lubricants can significantly reduce micropitting and extend gearbox life. Maintenance practices like oil change intervals, filtration, and keeping the oil cool should also be scrutinized. These combined actions could buy you some time before a full gear replacement becomes inevitable.
You could consider exploring the option of applying a high-performance, anti-wear additive to the oil. It could possibly slow down the wear process and possibly even help restore some of the damaged surfaces. Laser surface engineering, if I'm not mistaken, is also a treatment method that can mitigate micropitting. It might be worth looking into. Try to recall the name of that product you came across at the Reliability Show though, it might well be a viable solution too. Also, a regular monitoring and maintenance program can do wonders to prolong gearbox life. It might be a costly upfront investment, but you'll save a whole lot on emergency repairs and unplanned downtime over the long run.
It sounds like you might be referring to a process called "gear surface densification," which can indeed help extend the life of your gearboxes despite existing micropitting. I've had experience with this technique, and it can provide substantial improvements in the current state of your gears by compacting the metal surface fissures and wear zones. However, keep in mind that the method isn't a permanent fix and only postpones the need for a full replacement. In addition to this, make sure you are following a strict lubrication schedule with high-quality lubricants as this can also significantly reduce micropitting progression.
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Answer: - Common signs include high iron particulates found in oil analysis, unusual noise during operation, decreased efficiency, and visible signs of wear on the gear teeth.
Answer: - One option is to explore metal treatments that can be applied on-site to restore the surface of gears. These treatments may help mitigate the effects of micropitting and wear, thereby prolonging the gears' lifespan.
Answer: - Not necessarily. If a new set of gears is not currently feasible due to budget constraints, exploring alternative options like metal treatments to address the issue can be a cost-effective way to extend the gears' lifespan.
Answer: - Information about metal treatments for gears can often be found at industry events like the Reliability Show, where new technologies and solutions are showcased. Additionally, reaching out to gear specialists or manufacturers may provide insights into suitable treatments for specific gear issues.
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