As a core component of mechanical transmission systems, gear shafts often suffer wear and tear due to bearing damage (e.g., a shaft with a diameter of 280mm worn down to 268mm, with the deepest wear reaching 6mm). Traditional offline repair methods require extensive disassembly, welding that is prone to deformation, and the customization of new shafts, which involves long lead times and high costs, making it difficult to meet urgent needs.
1.The Complete Process of On-Site Repair Technology
Pre-Treatment
Surface Degreasing: Use an acetylene flame to heat the shaft body, removing oil contamination and carbonizing the surface to ensure a clean repair interface.
Surface Roughening: Use a grinding machine to grind the worn area, creating a uniform rough surface to enhance material adhesion.
Material Application and Fixture Positioning
Precise Calculation and Mixing: Calculate the required amount of two-component polymer composite material based on the volume of wear, and thoroughly mix until the color is uniform.
Rapid Application and Fixture Installation: Apply the material evenly to the worn surface, ensuring no bubbles, then immediately install the custom fixture mold to precisely control the repair dimensions.
Curing and Assembly
Material Curing: Control curing time and temperature according to material properties to ensure complete cross-linking and achieve mechanical strength.
Bearing Hot Installation and Precision Inspection: Simultaneously heat the bearing to the specified temperature (e.g., electromagnetic induction heating) to expand it, remove the fixture, and quickly install the bearing; clean excess material and inspect shaft diameter tolerance and surface roughness to ensure assembly precision.
2.Core Technical Advantages
High-Efficiency Non-Disassembly: Only the worn areas are exposed for repair, reducing the repair cycle by over 80% compared to traditional processes and minimizing downtime losses.
No Thermal Stress Damage: The entire process is conducted using cold technology, avoiding shaft deformation or material performance degradation caused by high temperatures from welding, ensuring shaft structural safety.
Cost-Effective and Reliable: No need to replace the shaft or rely on large equipment; the material cost is low, and the repair layer exhibits excellent impact resistance and wear resistance, with a service life approaching that of original components.
Wide applicability: Suitable for materials such as steel and cast iron, capable of repairing various damage forms including uniform wear, grooves, and uneven wear, and flexibly adaptable to equipment in industries such as power, cement, and metallurgy.