In the course of creating immense wealth, manufacturing industry has excessively consumed the resources and energy in the earth, and seriously polluted the environment. To take progress as the sustainable development way, save resource and improve environment, our nation has been advocating to construct the cycle economy and saving-oriented society. Taking the remanufacturing engineering as the representative, the “4R” rule (Reduce, Reuse, Recycle and Remanufacture) is the important measure to get the goal. Remanufacturing engineering is the industrialization of high-tech maintenance of the waste and worn productions, and is one of the most active factors in “4R”. The development of high and new technology takes the important effect to promote the remanufacturing engineering.

Nowadays, issues on population, environment and resource have become the world’s attentive focus. Sustainable development has been widely accepted around the world. As one of the biggest waste generator and resources consumer, manufacturing industry is facing more challenges as well as opportunities. In order to reduce both resource consuming and waste discharging effectively, traditionally manufacturing mode should be improved. Newly emerged creative technologies and strategies, including green design, green manufacturing and cleaner production, are regarded as the radical resolvent for current environment and resource issues and they will be the only way in the future that manufacturing will evolve. In this paper, a serial of research on green design/manufacturing and cleaner product theoretically and practically was presented. These creative technology and strategy will give strong support to ‘green’ the whole electromechanical designing and manufacturing processes.

A machining system is a typical manufacturing system. A green manufacturing function framework of machining systems is structured to describe the traits of input, output and control elements in the system. Based on the function framework, the green manufacturing problem framework of machining systems is presented. The green manufacturing problems in machining systems are classified into three classes and related series of subclass problems. The three classes of problems in the green manufacturing problem framework are the problems of the minimization of resource consumption, the minimization of environmental discharge, and the synthesized minimization of both of them. A series of investigations and practices on green manufacturing in machining system, performed by the authors for quite a long period, are introduced in brief, such as the optimizing system for raw material cutting, the matching system for energy-saving in machining, the design of highly efficient dry hobbing machine tools, the multi-objective decision-making model for green manufacturing in machining systems, and the decision-making supporting system for green manufacturing in machining processes.

The first automobile engine remanufacture company in China, Jinan Fuqiang Power Co, Ltd, was introduced. The engine remanufacturing technological process of this company was described. The benefit statistic of remanufacturing 10 000 Styer engines were analyzed, and the contribution of engine remanufacturing to cycle economy was predicted. The results show that remanufacturing engineering could use the maximal additional values of obsolete engines, and make contributions to materials conservation, capital saving, energy conservation and environment protection. 10 000 engines are supposed to be remanufactured per year, the following benefits would be obtained: reclaiming additional values of RMB3.23 hundred million, saving metallic materials about 7.65 thousand tons, saving energy of 16 million kilowatt-hours, reducing emission of CO₂ about 11.3–15.3 thousand tons, and providing employment for 500 persons. According to the survey and analysis, tremendous benefits will be gained by the year of 2020. For example, reclaiming additional values per year of 1424–2236 hundred million RMB, saving energy per year of 60–90 hundred million kilowatt-hours, reducing emission of CO₂ about 6.67–9.69 million tons. It can be deduced that developing remanufacturing will play an important role in enriching the cycle economy and accelerating the development of national economy.

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.

Virtual manufacturing is fast becoming an affordable technology with wide-ranging applications in modern manufacturing. Its advantages over existing technology are primarily that users can visualize, feel involvement and interact with virtual representations of real world activities in real time. In this paper, a virtual cutting system is built which can simulate turning process, estimate tool wear and cutting force using artificial neural network etc. Using the simulated machining environment in virtual reality (VR), the user can practise and preview the operations for possible problems that might occur during implementation. This approach enables designers to evaluate and design feasible machining processes in a consistent manner as early as possible during the development process.

To improve the solid lubricity on the worn surface of frictional-pairs, a convenient and simple brush-painting technique was utilized to prepare the solid lubrication graphite coatings. The bonding between the coatings and substrate is good. To examine the influence of the different graphite contents on the tribological properties of the graphite coatings, the comparison experiments were carried out on the ring-on-block friction tester. The tribological results show a change law of saddle-shape between the tribological properties of graphite coatings and graphite content. When the amount of graphite is up to 28 g, the tribological properties of graphite coating are the best. The excellent anti-friction of the graphite coating is associated with the close-packed hexagonal crystal structure of graphite.

Four different topics for high-temperature components, namely the development of the assessment codes for the structural integrity of high-temperature components, the application of continuous damage mechanics and probabilistic damage mode on the life assessment of high-temperature components, the life extension for high-temperature components and a proposed strategy for remanufacturing of high-temperature components were discussed in this paper. These topics should provide some important insights for the design and re-design of high- temperature components.

Some important developments of residual stress researches for coating-based systems were studied. The following topics were included the sources of residual stresses in coatings: error analysis of Stoney’s equation in the curvature method used for the measurement of coating residual stress, the modeling of residual stress and some analytical models for predicting the residual stresses in coatings. These topics should provide some important insights for the fail-safe design of the coating-based systems.

To evaluate the environmental, economic, energy performance of biomass ethanol fuel in China and to support the decision-making of biomass ethanol energy policy, an assessment method of life cycle 3E (economy, environment, energy) was applied to the three biomass ethanol fuel cycle alternatives, which includes cassava-based, corn-based and wheat-based ethanol fuel. The assessments provide a comparison of the economical performance, energy efficiency and environmental impacts of the three alternatives. And the development potential of the three alternatives in China was examined. The results are very useful for the Chinese government to make decisions on the biomass ethanol energy policy, and some advises for the decision-making of Chinese government were given.

Biomass ethanol fuel is not only renewable but also environmental-friendly. Guangxi Zhuang Autonomous Region is developing the cassava-based ethanol fuel. Economical performance of the project is the key issue. The traditional life cycle economical analysis is just a static calculation process. Uncertainty is the character of cassava yield, cost of cassava plant, cassava price, tax rate and gasoline price, and the economical performance of the project is determined by these aspects. This study proposes an economical model of cassava-based ethanol fuel. The method of Monte Carol is used to simulate the economical performance. This method conquers the shortage of the traditional way. The results show that cassava-based ethanol fuel can get survived when the tax is exempted. Finally, the study also evaluates the potential of the economical performance.

This paper used Baumel Jr. and Seeger’s approach estimating fatigue parameters of 48MnV with 3Cr13 coatings. The fatigue life of the crankshaft of a six-cylinder engine, repaired by twin arc spraying 3cr13 deposits, is respectively calculated using different damage model such as S-N method, normal strain approaches, SWT-Bannantine approaches, shear strain approaches, and fatemi-Socie method based on dynamical simulation and FE analysis of crankshaft. The results indicate that the traditional calculation is conservative and that the life of crankshaft repaired by arc spraying is sufficient.

Life-cycle assessment (LCA) is environmental evaluation of products, materials, and processes over their life cycle. Truncation uncertainty and corresponding uncertainty are main problems occurred in process life cycle assessment (PLCA) modeling and economic input-output life cycle assessment (EIOLCA) modeling. Through combination of these two modelings in different life cycle stage and use of an uncertainty reduction strategy, a hybrid life cycle assessment modeling method was proposed in this study. Case studies were presented on gasoline-powered motorbikes (M-bike) and electricity-powered electric bike (E-bike). Web-based software was developed to analyze process environmental impacts. Results show that the largest part of life cycle energy (LCE) is consumed at use stage. Less energy is consumed in life cycle of E-bike than that of M-bike. GWP (Global Warming Potential), CO (Carbon Monoxide), PM10 (particulate matter) emission of M-bike are higher than that of E-bike, especially at use stage, AP (acidification Potential) emission of E-bike is higher than that of M-bike. Comprehensively, E-bike is energy efficient and less emitting, and better choice for urban private transportation.

The life cycle index of remanufactured engines was assessed by using the method of life cycle assessment (LCA). A remanufactured engine of a certain domestic brand was taken as researching object. Engine reproducing engineering was investigated from three aspects which were energy, material and environment. The application of LCA on remanufacturing engines was discussed in detail with a practical case. The results indicate that remanufacturing an engine can save 55 kg steels, 8.3 kg aluminum and 113 kW · h electric powers and reduce emissions of 565 kg CO₂, 6.09 kg CO, 1.01 kg NO_x, 3.985 kg SO_x and 288.725 kg solid waste. The remanufacturing of engines possesses great economic value and practicability.

Two dynamic grey models DGM (1, 1) for the verification cycle and the lifecycle of measuring instrument based on time sequence and frequency sequence were set up, according to the statistical feature of examination data and weighting method. By a specific case, i. e. vernier caliper, it is proved that the fit precision and forecast precision of the models are much higher, the cycles are obviously different under different working conditions, and the forecast result of the frequency sequence model is better than that of the time sequence model. Combining dynamic grey model and auto-manufacturing case the controlling and information subsystems of verification cycle and the lifecycle based on information integration, multi-sensor controlling and management controlling were given. The models can be used in production process to help enterprise reduce error, cost and flaw.

To monitor the stress state of prestressed reinforcement in large reinforcement prestressed structure, two sensing structures, namely the direct spiral-winding structure and sawtooth modulated structure, were designed based on the ordinary communication optical fiber. The sensing theories were analyzed, and the experimental studies were also carried out. The quasi-distributed sensing system based on optical time domain reflective technology was established. The detection wavelength and spatial resolution were analyzed, and the estimation formula of maximal number of sensing point was also given. The results show that the system can realize the quasi-distributed test of measurand with single fiber, which helps to simplify the in-out wires. Moreover it can take on the important task of long-term and continuous monitoring of prestress, which helps to realize the life cycle detection of prestress, and play an important role in the estimating of bridge health state.

A particle swarm optimization (PSO) algorithm improved by immunity algorithm (IA) was presented. Memory and self-regulation mechanisms of IA were used to avoid PSO plunging into local optima. Vaccination and immune selection mechanisms were used to prevent the undulate phenomenon during the evolutionary process. The algorithm was introduced through an application in the direct maintenance cost (DMC) estimation of aircraft components. Experiments results show that the algorithm can compute simply and run quickly. It resolves the combinatorial optimization problem of component DMC estimation with simple and available parameters. And it has higher accuracy than individual methods, such as PLS, BP and v-SVM, and also has better performance than other combined methods, such as basic PSO and BP neural network.

In order to investigate the physical mechanism of metal magnetic memory testing, both the influences of earth magnetic field and applied stress on magnetic domain structure were discussed. Static tension and fatigue tests for low carbon steel plate specimens were carried out on hydraulic servo testing machine of MTS810 type and magnetic signals were measured during the processes by the type of EMS-2003 instrument. The results indicate that the initial magnetic signals of specimens are different before loading. The magnetic signals curves are transformed from initial random to regular pattern due to the effect of two types of loads. However, the shape and distribution of magnetic signal curves in the elastic region are different from that of plastic region in tension test. While in fatigue test those magnetic signals curves corresponding to different cycles are similar. The H_p(y) value of magnetic signals on the fracture zone increases dramatically at the breaking transient time and positive-negative magnetic poles occur on the two parts of fracture zone.

To test the magnetic signals leaked from the surface of specimens during loading, the experiments of the static tensile of medium carbon 45^# steel were carried out. The results show that the magnetic field strength values rapidly vary when the load began, and the curves of the magnetic field strength change from irregularity to regularity with the increase of the load. Furthermore, by comparing with the state of on-line testing, it is found that the magnetic signals of out-of-line testing has more practicability. In the course of loading, though the dots of passing zero of the magnetic field strength continually changed their positions and quantities, the last rupture places were always approached by the dots of passing zero since the elastic loading phase. Some certain relations should exist between external stress and changing of magnetic signals inside the material, and correlative explanation is made based on dislocation theory and the mechanism of magnetic domain action, which provides the basis for further research of magnetic memory.

The fatigue behaviors of 48MnV steel, both uncoated and coated with different thicknesses of 3Cr13 deposits using twin arc spraying, were investigated. The fatigue properties of the 48MnV steel, determined under axial loading conditions, can be substantially decreased by coating 3Cr13 films, deposited by twin arc spraying. And the fatigue behavior of the thinner coatings is better than that of the thicker ones, of which the fatigue limits decrease by 9%–14%. The decrease in fatigue life attributes to the less mechanical properties of the coatings in comparison with those of the substrate, their relative bad bonding strength and trapped oxide or Al₂O₃ particles retain in the matrix after blasting responsible for the initiation of fatigue cracks.

Corrosive failure is frequently found in petrochemical pipelines which may lead to the leakage of the pipes and even the shutdown of the system. However, the corrosion mechanism is still not well understood due to the complex service environment, e.g. the corrosive fluids and the long term operation at higher temperature. The corrosion behaviour of a petrochemical pipe elbow was evaluated via visual examination and microanalysis with optical microscope and scanning electron microscope (SEM) together with energy dispersive analysis X-ray (EDAX). The corresponding corrosion mechanisms, the combination of grain boundary attach and the crevice attach together with the flow-accelerated corrosion, were proposed consequently.

The severe wear of separating ring is considered to be a main reason which leads to the improper declutch of the main clutch of heavy vehicles. The wear mechanism of the separating ring is not well understood. Scanning electron microscopy and transmission electron microscopy were employed to analyze the surface features and dislocation characteristics of the separating ring. The typical features of furrows and rolled tongue-like metal were found on the surface of separating ring by scanning electron microscopy observation, which can be considered as a major indication of the grain-abrasion. A zone of high density dislocation was noted on the subsurface of the separating ring by transmission electron microscopy observation, which implies the contribution of the severe impact on the surface of the separating ring in the wear process. The influences of the structure of the separating ring, the service condition and the in-service stress distribution on the wear behavior, were also analyzed. The results show that the failure of separating ring results from the impact wear and grain-abrasion together with the plastic deformation.

Remanufacturing system is a term of green system project which conforms to the national sustainable development strategy. With the demand of the high adaptability of the varieties of waste machining parts, the short product cycle, the low machining cost and the high product quality are offered. Each step of the remanufacturing system from the beginning of the scanning to the accomplishment of the welding was investigted. Aiming at building a remanufacturing system based on totally automatic MIG surfacing via robot, advanced information technology, remanufacturing technology and management, through the control of the pretreatment and the optimization to minimize the time of remanufacturing and realize the remanufacturing on the terminal products of varieties, were applied. The steps mainly incude: 1) using the visual sensor which is installed at the end of the Robot to rapidly get the outline data of the machining part and the pretreatment of the data; 2) rebuilding the curved surface based on the outline data and the integrated CAD material object model; 3) building the remanufacturing model based on the CAD material object model and projecting the remanufacturing process; and 4) accomplishing the remanufacture of the machining part by the technology of MIG surfacing.

This paper deals with the scanner exterior calibration algorithm when the scanner is arranged by the robot and the object scanned is fixed on a rotate device in the Robot Remanufacturing System. The method of calibrating the relationship between the scanner coordinate and the robot Tool₀, such as the rotation, R_x, R_y, R_z, and the transformation X, Y, Z is studied. The data of Tool₀ can be directly obtained from the relationship with the robot base-coordinate. So, the coordinate relationship between the scanner coordinate and the robot base coordinate can be easily gotten. This paper explains the basic algorithm theory, computing method, data collecting process and the resulted data in detail. The calibration algorithm is deduced under the orthogonal coordinate.

The volume tendency of in-use and end-of-life computers in China were analyzed; the emerging danger of obsolete computers by incorrect treatment was summarized; the integration disposal technologies based on 3R (recycle, remanufacture and reuse) engineering aiming at monitors, electronic devices, metals, plastics materials, and overall computers were put forward; the economic and social benefits were also analyzed. The results show that the integration disposal process of obsolete computer is an optimum approach to save the resource of electromechanical products. Remanufacturing and disposal 100 thousand obsolete computers per year can create profits about RMB10 million yuan and provide employment for 300 persons. It can be deduced that there are great potential opportunities for the obsolete computers disposal industry containing recycle, remanufacture and reuse engineering.

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.

Residual fatigue strength of 48MnV crankshaft was studied and analyzed based on safety factor. Three different status crankshafts were used to the hop-up tests, which maintain new after 500 h hop-up tests and after 1 000 h hop-up tests. Then, crankshafts were cut into unit cranks. The unit cranks were used to do endurance bending tests to get the residual fatigue strength. Finally, the results were analyzed based on safety factor. The results show that safety factor of crankshaft descends a little with the increase of the running time, and the residual safety factor is still much bigger than the endurable safety factor. Furthermore, after the crankshaft accomplishes a full life cycle, the residual fatigue strength of the crankshaft is enough to remanufacture and fulfill the next life cycle.

The Chinese obsolete electric and electronic equipments (EEE) recycling and disposal system on the point of view of legislation, education and dissemination were discussed, because of the highly increasing volume of electric and electronic products and that of its obsoletes today in China. The legislations and responsibilities of government, industry and consumer were discussed based on the balance of benefit and responsibility depending on the realization of their benefits in the whole life cycle of products and its status in the whole value chain. Not only the legislation and establishment of the so called “compulsory discarding system” will be a possible and effective solution to the difficulty of the obsolete collection and recycling for obsolete electric and electronic reclaiming industry, but also the education and dissemination. Education and dissemination were discussed as an important role which will emphasize the adjusting of policy and law on the development of electric and electronic industry production and its reclaiming. The education of stockholders’ environmental responsibility and the advocating of responsibility sharing should be implement for industry and consumer. Chinese EEE industry should emphasize the control of natural source, and should implement the environmental benign design in their production, such as design for dismantling, no dismantling, thermal treatment and green design. The perspectives for the way to advocate a harmonic society for Chinese people were described.

The end-of-life vehicle recycling was studied based on the disassembly. The end-of-life recycling and the disassembly were reviewed and discussed. A disassembly experiment of an end-of-life engine was carried out, which strictly recorded the process of dismantling. Based on the results, a model of the end-of-life recycling was presented. In this model, the end-of-life parts were classified by three ways which included to recycle directly, to recycle after remanufacturing and to discard. By using this model, the dismantling efficiency and the recycling rate can be improved. Also, it obtains a good result after used in a dismantling factory.

A comprehensive assessment index system was established. The mechanical recycling process of printed circuit board was evaluated according to the comrehensive evaluation index system using the fuzzy analytic hierarchy process. A process assessment software system of mechanical recycling was established to evaluate different recycling technologies. And the software system was developed in the environment of VB 6.0 and Access 2000.

The present situations of waste refrigerators recycling and disposing were analyzed. Three key technologies of layout design of recycling plants of waste refrigerators were presented as follows: 1) establishment of recycling process of waste refrigerators; 2) the general plane layout of recycling plants; 3) the detailed layout of workshops of recycling plants. The focus of the three key technologies is to tackle the problem of the detailed layout of workshops of the recycling plants. By adopting Petri net, the model of logistics system of workshops was established and then optimized, and finally the detailed layout chart of recycling plants was gained. By adopting E-factory, the recycling plants were simulated. The results show that the method mentioned is effective.

The issue of reducing energy consumption for the job-shop scheduling problem in machining systems is addressed, whose dual objectives are to minimize both the energy consumption and the makespan. First, the biobjective model for the job-shop scheduling problem is proposed. The objective function value of the model represents synthesized optimization of energy consumption and makespan. Then, a heuristic algorithm is developed to locate the optimal or near optimal solutions of the model based on the Tabu search mechanism. Finally, the experimental case is presented to demonstrate the effectiveness of the proposed model and the algorithm.

Ni/n-SiO₂ composite coating was electrodeposited by brush-plating with pulse-reverse current(RC). The morphology, hardness, and tribological properties of the coating were investigated and compared with those of Ni and composite coatings electrodeposited with direct current (DC). The results indicate that Ni/n-SiO₂ composite coating electrodeposited by RC, because of RC and the nano powders, has denser coating, finer crystal grains, higher hardness (HV650.0, nearly 1.5 times higher than that of Ni coating electrodeposited by DC) and lower friction coefficient (nearly 0.62), as a result, in the wearing experiment, the Ni/n-SiO₂ composite coating electrodeposited by RC has the least worn loss. So this kind of coating has better wear resistance. And RC electro brush-plating can be used as a new technology of brush-plating in the area of wear resistance.

Sand-wear resistance of nano scale alumina particle reinforced nickel matrix composite coating (n-Al₂O₃/Ni) prepared by brush electroplating technique was investigated via wear tests in sand-contaminated oil lubricant, comparing with that of AISI1045 steel and brush electroplated Ni coating. Effects of testing load, sand content and sand size on worn volume of the three materials, and also coating surface roughness on worn volume of the brush electroplated coatings were accessed. Results show that the worn volume of all the three materials increases with increasing of testing load, sand content and sand size. In the same conditions, n-Al₂O₃/Ni composite coating has the smallest worn volume while AISI1045 steel has the largest because of the n-Al₂O₃ particle effects. As to n-Al₂O₃/Ni and Ni coatings, the surface-polished coatings have obviously lower worn volume than the as-plated coatings. The brush electroplated n-Al₂O₃/Ni composite coating was employed to remanufacture the sand-worn bearing seats of a heavy vehicle and good results were gained.

The tribological behaviors of the nano-diamond particles including the nano-diamond and the nano-diamond modified were studied at high temperature using SRV multifunctional test system. The worn steel surfaces were analyzed by means of X-ray photoelectron spectroscopy (XPS). The results show that nano-diamond particles can obviously improve the antiwear and friction reducing properties of the base oil at high temperature and the high load. The friction coefficient of the nano-diamond is very low at 200 °C when the test load is not more than 20 N. This tribological behaviors should attributed to the similarly to “ball bearing” lubrication action of the nano-diamond particles, so the movement between tribological pairs become sliding/rolling. The nano-diamond modified by dimer ester possesses excellent antiwear and friction reducing performance at 500 °C and load 500 N. The tribochemical reaction film between the nano-diamond particles and the renascent wear surface plays dominating lubrication role and the presence of the dimer ester on the rubbing surface can be propitious to form lubrication film containing nano-diamond on the worn surface at high temperature and high load.

The surface modified nanocopper particles were prepared with chemical reduction method. The wear test was carried out on a T-11 ball-on-plate friction and wear tester made in Poland. The material of the upper sample was GCr15 and the counterpart was AISI-1045 steel. The morphologies of the worn surfaces of the samples were observed by optical microscope and scanning electron microscope, while the element distributions on the worn surfaces were determined by means of electron microprobe analysis. As the results, a film mainly made of Cu is formed on the worn surface. The film on the surface of the still upper sample is thicker than that formed on the revolving counterpart. At the edge of the groove of the worn surface made by the milling before test there is Cu element observed obviously, but there is not any Cu element in the bottom of the groove. A possible action mechanism of the film is suggested. The friction movement can induce reactivity of the metal and continuously produce activation surface. It benefits the film formed by nano-Cu in lubricant on the worn surface. Hardness and modulus of nano-Cu films were successfully measured and analyzed by the nanoindentation instrument. The results show that the hardness and modulus of the films are lower than those of the initial surface.

Nano-SiO₂ particles strengthened Ni-based composite coating was designed and prepared on steel substrate. The structures and nanoparticle content of the nano-SiO₂/Ni composite coating were determined by SEM, EDS and TEM; and the micro mechanical properties were tested by nano-indentation technique. The results show that 56% of particles in the solution are dispersed in size of less than 100 nm, the content of nanoparticles co-deposited in the coating doubles and structure of the coating is more compact and uniform than that of Ni coating. Nano-SiO₂/Ni coating exhibits excellent micro mechanical properties, and the nanohardness and elastic modulus are 7.81 GPa and 198 GPa, respectively, which are attributed to finer crystal strengthening, dispersion strengthening and high-density dislocation strengthening of nano-SiO₂ particles to the composite coatings.

As a new spraying technology used in the remanufacturing engineering, electro-thermal explosion spraying holds a lot of advantages. Electro-thermal explosion spraying coating aliquation phenomena are reduced and non-crystal, micro-crystal and millimicron-crystal and other microstructure are formed. The corrosion-resistance ability of electro-thermal explosion spraying coating in high temperature environment was surveyed respectively. SEM equipped with EDS was employe to analyzed the microstructure of spraying coating before and after corrosion. The corrosion-resistance mechanism of the spraying coating was discussed.

An automatic brush-plating system was developed for component remanufacturing. With this system, Ni/nano-alumina composite coatings from an electrolyte containing 20 g/L nano-alumina particles were prepared. Microstructure, surface morphology, microhardness and wear resistance of automatically plated coating and manually plated coatings were investigated comparatively. The results show that the automatically plated coatings are relatively dense and uniform and have lower friction coefficient of 0.089 under lubricant condition, when compared with manually plated coatings with friction coefficient of 0.14.

Nano-copper used as lubrication oil additive has good tribological property and active self-repairing effect for friction pairs. The reduction in liquid phase for preparing nano-additive is one of the most common method. Nano-copper was prepared by reduction in liquid phase. The different project and routine practice for preparing nano-copper were researched. The dispersion problem of nano-copper was investigated by surface treatment and high dispersion. The particles dimension, the dispersion stability and the purity of nano-copper were characterized by TEM and XRD. The conclusion indicates that the methods of the preparation and dispersion can obtain 20 nm copper additive with good dispersion property in lubrication oil.

Electro-thermal explosion directional spraying was used to prepare the stellite coating on substrate of the AISI 1045 steel. The morphologies of cross-section and worn scar, porosity, distribution of elements, micro-hardness and wear resistance of the coating were determined by means of SEM, EDAX, micro-hardness tester and sliding wear tester. Because of the compact construction, good bonding and high hardness, the coating is characterized by good wear resistance. The results show that the mainly failure mode of the stellite coating is micro-plowing.

Based on the advanced integrated technology of materials preparation and formation, a new pattern Zn-Al-Mg-RE anti-corrosion coating for steel structure sustainable design was manufactured by cored wires and high velocity arc spraying (HVAS) technologies. The developments of thermally sprayed coatings for steel structure protection were described. Based on Al, Zn, Zn-Al and Zn-Al-Mg coatings, the anti-corrosion properties of new-pattern Zn-Al-Mg-RE coating were evaluated through electrochemical methods including electrochemical polarization and electrochemical impedance spectroscopy (EIS) coupled with SEM and XRD. The models of Zn-Al-Mg-RE coating undergoing corrosion with the initial pinhole defect and the latter with accelerated products were also discussed. The results show that Zn-Al-Mg-RE coating exhibites excellent corrosion resistance for long-term immersion, which is helpful for the sustainable design of steel structure in aggressive corrosion conditions. And the corrosion products seem to possess certain self-sealing function.

Oleic acid surface-modified Cu nanoparticles with an average size of 20 nm were prepared by liquid phase reducing reaction. The tribological performance and mechanism of nanocopper as additive were studied by means of tribotester, scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS) and nanoindentation instrument. The results indicate that the modified nanocopper additive can significantly improve the wear resistance and reduce friction coefficient of base oil. A copper protective film is formed and contributes to the excellent tribological properties of nanocopper additive. On the basis of the film forming mechanism, a new in-situ repair method was designed and used to repair wear-out-failure injection pump plunger and barrel. Furthermore, the current research progress of nanoparticles as green energy-saving lubricating oil additives were presented.

Fe-Al intermetallics with remarkable high-temperature intensity and excellent erosion, high-temperature oxidation and sulfuration resistance are potential low cost high-temperature structural materials. But the room temperature brittleness induces shape difficult and limits its industrial application. The Fe-Al intermetallic coatings were prepared by high velocity arc spraying technology with cored wire on 20G steel, which will not only obviate the problems faced in fabrication of these alloys into useful shapes, but also allow the effective use of their outstanding high-temperature performance. The Fe-Al/WC intermetallic composite coatings were prepared by high velocity arc spraying technology on 20G steel and the oxidation performance of Fe-Al/WC composite coatings was studied by means of thermogrativmetic analyzer at 450, 650 and 800°C. The results demonstrate that the kinetics curve of oxidation at three temperatures approximately follows the logarithmic law. The composition of the oxidized coating is mainly composed of Al₂O₃, Fe₂O₃, Fe₃O₄ and FeO. These phases distribute unevenly. The protective Al₂O₃ film firstly forms and preserves the coatings from further oxidation.

The present status and development trends of nano-composite coatings were briefly introduced. The nano-SiO₂ was dispersed into crylic acid resin by ultrasonic wave and high-energy ball milling, the influence of nano-SiO₂ on shielding property of coatings was investigated. Relation between particle size distribution of original nano-SiO₂ and its dispersal in water and alcohol after treatment were analyzed, respectively. The ultraviolet permeation rate of coatings filled with nano-SiO₂ was detected by ultraviolet spectral photometer. And the particle size distribution of coatings was examined by TEM. The results show that particle size distribution is comparative convergence and smaller one order of magnitude after dispersal treatment. The size of most nano-SiO₂ in coatings is smaller than 100 nm, which indicates that the amount of nano-SiO₂ in the resin is 20% (solid content of resin), the permeation rate of ultraviolet of composite coatings decreases to 20%. The research of its excellent ultraviolet shielding property mechanism indicates minor size and high surface energy of nano-SiO₂ can produce different absorption, reflection and scatter actions to different wavelengths.

The finite element method (FEM) and the boundary element method (BEM) are often adopted. However, they are not convenient to spatially vary thermal properties of functionally graded material (FGM). Therefore, the method of lines (MOL) is introduced to solve the temperature field of FGM. The basic idea of the method is to semi-discretize the governing equation into a system of ordinary differential equations (ODEs) defined on discrete lines by means of the finite difference method. The temperature field of FGM can be obtained by solving the ODEs. The functions of thermal properties are directly embodied in these equations and these properties are not discretized in the domain. Thus, difficulty of FEM and BEM is overcome by the method. As a numerical example, the temperature field of a plane problem is analyzed for FGMs through varying thermal conductivity coefficient by the MOL.

Compared with the single sulphurating treatment, the duplex treatment of nitrocarburizing-sulphurating can more effectively improve the properties of steel such as friction-reducing, wear resistance and anti-scuffing. Under the same processing parameters, the sulphide layers were fabricated on the surface of CrMoCu alloy cast iron by single ion-sulphurating treatment and nitrocarburizing-sulphurating duplex treatment, respectively. Through the analysis of the sulphide, the effect of the nitrocarburizing on the fabrication of the sulphide layer was investigated. And the result shows that the fabrication of sulphide layer is promoted by the nitrocarburizing treatment.

Nanostructured n-Al₂O₃/Ni feedstock for thermal spraying was manufactured by the method of chemical wrapping and spray drying. The nanostructured coating was sprayed with this feedstock. Tribological properties of the coatings and steel 45# were tested. Within the testing range, the friction coefficient of coatings against GCr15 steel decreased and the mass loss of coatings increased at first then decreased with the increase of load. Under each load, the coatings’ fraction coefficients and wear losses were lower lower than that of steel 45#. Scanning electron microscopy and energy dispersive spectrometer analysis show that adhesion is the dominating wear mechanism, and fatigue exists at the same time. Material transferred from counter-part to the coating is the main factor which influences the coatings’ friction coefficient and wear losses.

The corrosion resistance of NiCrAl+(ZrO₂+Y₂O₃) thermal barrier coating, formed with the plasma spraying technique, on the 18 - 8 steel surface was investigated. The phase structure and morphology of the coating were analyzed by means of X-ray diffraction (XRD) and scanning electron microscopy (SEM). The electrochemical corrosion behavior of the coating in 1.0 mol/L H₂SO₄ solution was studied by using electrochemical measurement methods. The results show that the gradient plasma spraying coating is composed of the NiCrAlY coating and the (ZrO₂+Y₂O₃) top coating, and the coating thickness is 360 µm. The microhardness of coating reaches 1 100 HV. The corrosion resistance of the plasma sprayed coating of the 18 - 8 steel surface is about 5 times as great as that of the original pattern. The corrosion resistance of the coating is enhanced notably.

NiCrAlY+(ZrO₂+Y₂O₃) thermal barrier coating was prepared on the surface of refractory steel 1Cr18Ni9Ti with plasma spraying technique. The phases and microstructure of the thermal barrier coating were determined by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The results show that the bonding between thermal barrier coating and substrate is sound. The surface hardness of 1Cr18Ni9Ti reaches up to 1 000 HV, but that of substrate is only 300 HV. The patterns sprayed with CoNiCrAlY+(ZrO₂+Y₂O₃) ceramic coating have a good heat insulation effect at 800 °C for heat insulation temperature difference reaches 54 °C, which increases the operating temperature and service life of refractory steel.