Zhang Xiancheng

Failure analysis used for remanufacturing of steel rolling components

The guide-pieces, used in the process line of steel rolling, were the important components. The guidepieces, which were slide contacting with the rolled-piece, had a high temperature and high speed. The wear was very serious. The results from failure analysis showed that there were three failure forms in the guide-pieces: the first was the wear during heat friction, the second was the heat fatigue under the cycle of deep heating and deep cooling, and the third was the impact rupture. Among them, the wear was the main reason. To the wear of guidepieces, there were four mechanisms, namely abrasive wear, adhesive wear, fatigue wear and corrosion wear. The failure analysis to the guide-piece laid the foundation for its remanufacturing.

Residual stresses in coating-based systems, part I: Mechanisms and analytical modeling

Thin films and multi-layered coatings comprised of different classes of materials are often used for various functional devices. The thermo-mechanical integrity of these systems is becoming a major concern and is strongly related to the residual stresses because of the fabrication processes. In this paper, the sources of the residual stresses in the coating-based systems and the concept of “misfit strain” were briefly reviewed. Analytical models were developed to predict the residual stresses in multi-layered film structures or coating-based systems using the force and moment balances. In addition, the residual stress distributions in the functionally and compositionally graded coatings were also analyzed.

Residual stresses in coating-based systems, part II: Optimal designing methodologies

In this part of the work, different cases are studied to illustrate the implementation of the analytical models that have been developed in Part I [Front. Mech. Eng. China, 2007, 2(1): 1–12]. Different topics are involved in the optimal design of coating-based systems. Some essential relations among material properties and dimensions of the coating and substrate and the residual stress variations are reflected. For the multilayered coating-based systems, some optimal design methodologies are proposed, such as the decrease in stress discontinuity at the interface between the adjacent layers, the curvature as a function of the coating thickness, the effect of the interlayer on the residual stress redistribution, and so on. For the single-layered coating-based systems, some typical approximations that are often used to predict the residual stresses in the coating-based system or bilayer structure are corrected. A simplified model for predicting the quenching stress in a coating is also developed.

Remanufacturing strategy for chemical equipment

Failure, especially induced by cracks, usually occurred in the service process of chemical equipment, which could cause the medium leakage, fire hazard and explosion and induced the personnel casualty and economic losses. To assure the long-term and safety service, it is necessary to apply the remanufacturing technology on the chemical equipment containing cracks. The recent research advances on the remanufacturing, the failure modes and the life extension technology for chemical equipment were reviewed. The engineering strategy of the remanufacturing for the chemical equipment was proposed, which could provide a reasonable and reliable technical route for the remanufacturing operation of chemical equipment. In the strategy, the redesign was also been considered.