Recent Applications

Internal Combustion Engines

Recent Data from Stock Building Supply (504 kb PDF)

Adobe Reader required for viewing the above document.

FUSION-TECH ENGINE NANO-TREATMENT INCREASES HORSEPOWER WHILE IMPROVING FUEL EFFICIENCY AND REDUCING HARMFUL EMISSONS

Using Marks driveshaft & wheel dynonometer at Gregory Poole Caterpillar, Raleigh, NC

2007 International 4700 DT466
  Driveshaft HP Wheel Load HP
RPM % Power Before After % +/- Before After % +/-
700 20% 220 220 0% 150 150 0%
1000 45% 245 240 -2.0% 150 155 3.3%
1200 52% 245 250 2.0% 175 175 0%
1500 60% 250 255 2.0% 200 200 0%
1800 80% 250 280 12.0% 245 245 0%
2000 85% 250 282 12.8% 260 290 11.5%
2150 90% 270 300 11.1% 275 300 9.0%
2350 100% 300 320 6.7% 305 345 13.1%

Class 8 Diesel Delivery Vehicle Analysis @ $3.00 per gallon - Before and After Treatment

Pre-Treatment MPG / Miles per Year / Gallons Used (G)
MPG 50,000 75,000 100,000 125,000 150,000 175,000 200,000
4 12,500 G 18,750 G 25,000 G 31,250 G 37,500 G 43,750 G 50,000 G
5 10,000 G 15,000 G 20,000 G 25,000 G 30,000 G 35,000 G 40,000 G
6 8,333 G 12,499 G 16,666 20,833 G 24,999 G 29,165 G 33,332 G
Post-Treatment MPG @ 15% Minimum Improvement
MPG  
4.6 10,416 G 15,625 G 20,832 G 26,041 G 31,250 G 36,458 G 41,664 G
G Saved 1,630 G 2,446 G 3,261 G 4,076 G 4,892 G 5,707 G 6,522 G
$ Saved $4,890 $7,338 $9,783 $12,228 $14,676 $17,121 $19,566
ROI 3.7 mo. 2.5 mo. 1.8 mo. 1.5 mo. 1.2 mo. 1.1 mo. > 1 mo.
 
5.75 8,333 G 12,500 G 16,666 G 20,833 G 25,000 G 29,166 G 33,332 G
G Saved 1,304 G 1,957 G 2,608 G 3,261 G 3,914 G 4,565 G 5,216 G
$ Saved $5,312 $5,871 $7,824 $9,783 $11,742 $13,693 $15,648
ROI 4.6 mo. 3.1 mo. 2.3 mo. 1.8 mo. 1.5 mo. 1.3 mo. 1.2 mo.
 
6.9 6,944 G 10,416 G 13,888 G 17,361 G 20,833 G 24,305 G 27,778 G
G Saved 1,087 G 1,629 G 2,174 G 2,717 G 3,258 G 3,803 G 4,348 G
$ Saved $3,261 $4,887 $6,522 $8,151 $9,774 $11,409 $13,044
ROI 5.5 mo. 3.7 mo. 2.8 mo. 2.2 mo. 1.8 mo. 1.6 mo. 1.4 mo.

Gun Barrels

CASE: Finnish ThermoWood Ltd

Finnish ThermoWood Ltd is located in Teuva, Finland. The thermo treatment (drying) process of the wood is carried out in big ovens, where the necessary air circulation is managed by fans. The company has got difficulties to find the suitable lubricant for the fan axle bearings located inside the oven in very hot and demanding conditions. The temperature inside the oven occasionally exceeds 220oC added with the friction heat created by the bearing-axle operation itself. Bearings have in worst cases got broken even on weekly bases. Last winter one of the total 5 axles in the oven lost 3 bearings in 3 weeks.

Different kind of greases with the dropping point over 240oC were tried and tested, but without any significant results. Greases tested were, for instance, Super Lube Plus PTFE-gel (NLGI-classification: 2, Viscosity 40oC: 365 mm2/s, Dropping point: Doesn't drop), a fully synthetic grease manufactured by Synco Chemical Corporation and Sentinel DSF 3000-grease (NLGI-classification: 1.5; Viscosity: 40oC: 675 mm2/s; Dropping point: Doesn't drop), a fully synthetic grease for extraordinary hot conditions.

On January 29, 2004, in connection of the installment of another new bearing, we decided to test a grease supplied by RVS*, a mixture of RVS nano-ceramics and a fully synthetic grease manufactured by the Swedish grease manufacturer Axel Christiernsson Ab (NLGI-classification: 2; Viscosity 40oC: 480 mm2/s; Dropping point: 280oC).

The temperatures of the wood and the current consumptions of the different fan units and other devices of the establishment (oven) are followed by the monitors of the control room. After a few hours of operation a reduction of 5% was noticed in the current consumption of the engine driving the treated fan. This is significant as only one bearing (the one inside the oven) of the total 4 bearings of the axle/engine line of the fan was treated with RVS grease-mixture. RVS mixture was added few times following the normal lubrication program.

After 13.5 weeks on April 30, 2004 the bearing finally got stuck. The useful life time of the bearing had increased 4-5-fold. When the bearing was disassembled, we found that the steel dial ring of the bearing was wrecked and the barrel-like balls (rollers) of the bearing had turned into wrong position thus jammed, which finally stuck the bearing. One could see by mere eyes that a transparent, glass-like and very smooth surface structure had been built on the friction zones of the inner and outer circumferences of the bearing (Picture No:1, right side.). It's obvious that the bearing would have lasted much longer still, if not the dial ring was damaged and destroyed.

The treated bearing: 2-row SKF CARB Toroid roller bearing type C2215K (external diameter 130 mm).

Picture No: 1. RVS-treated outer circumference of the bearing on the right. The new formed transparent, glass-like and very smooth surface structure can clearly be noticed. A normally lubricated similar kind of outer bearing circumference utilized in similar conditions and similar axle on the left. The differences of the roughness of the surfice structures are visible by bare eyes even from the photographed picture below.

Picture No: 2. A microscopic X-ray picture of a grinded edge of the RVS-treated bearing in Picture No: 1. The darkest area is synthetic plastic into which the metal was cast before grinding the edge. The light grey area is the original metal (bearing steel). The medium grey area is the metal ceramic layer built by RVS nano-ceramic compounds and the friction energy. The structure and thickness of the formed layer (about 15 μm) can be clearly seen. The scale down left.

* Fusion-Tech is RVS's exclusive licensee for the United States.

Back to top