Self-Repairing and Self-Sustaining Autonomous Machines

• US 20140050844A1
• Filed: 02/21/2012
• Published: 02/20/2014
• Est. Priority Date: 02/22/2011
• Status: Active Grant

• Current Assignee: George Washington University
• Original Assignee: George Washington University
• Inventors: Hsu, Stephen
• Granted Patent: US 10,737,358 B2
• Time in Patent Office: Days
• US Class Current: 427/140
• CPC Class Codes: B23P 6/00 Restoring or reconditioning objects straightening or restoring form of sheet metal, metal rods, metal tubes, metal profiles, or specific articles made therefrom B21D1/00, B21D3/00; repairing defective or damaged objects by casting techniques B22D19/10
• CPC Class Codes: C10M 125/04 Metals; Alloys
• CPC Class Codes: C10M 171/06 Particles of special shape or size
• CPC Class Codes: C10M 2201/14 inorganic compounds surface treated with organic compounds
• CPC Class Codes: C10N 2020/06 Particles of special shape or size
• CPC Class Codes: C10N 2030/06 Oiliness; Film-strength; Anti-wear; Resistance to extreme pressure
• CPC Class Codes: F16C 2223/30 Coating surfaces in general B05C, C23C
• CPC Class Codes: F16C 33/102 with grease as lubricant
• CPC Class Codes: F16C 33/104 in a porous body, e.g. oil impregnated sintered sleeve
• CPC Class Codes: F16C 33/1045 Details of supply of the liquid to the bearing
• CPC Class Codes: F16C 33/109 Lubricant compositions or properties, e.g. viscosity
• CPC Class Codes: F16C 33/14 Special methods of manufacture; Running-in
• CPC Class Codes: F16C 33/201 Composition of the plastic
• CPC Class Codes: F16C 33/208 Methods of manufacture, e.g. shaping, applying coatings

Abstract

The metallurgical composition of a machine surface may be determined. Based on the composition of the surface layer and its substrate materials, a mixture of pure metal nanoparticles, each coated with a monomolecular organic layer adsorbed on its surface can be mixed with catalysts, reaction initiators, and/or other necessary ingredients for the repair action of the machine surface, depending on the specific machine, operational type, and/or the nature of the damage. The nanoparticles are applied to the machine surface, the organic monolayer wears away from the nanoparticles under shear stresses and the nanoparticles adhere to the machine surface to form a repair layer on the machine surface, thereby providing a repaired surface.

Claims

1. A method of repairing a machine surface, comprising:

coating nanoparticles with an organic monolayer having adjustable bonding strength; and

applying the nanoparticles with the organic monolayer to the machine surface,

wherein the organic monolayer wears away from the nanoparticles under shear stresses and the nanoparticles adhere to the machine surface to form a repaired surface including a repair layer.

2. The method of repairing a machine surface according to claim 1, wherein the nanoparticles are encapsulated in polymeric pouches and the nanoparticles are applied to the machine surface when the polymeric pouches are ruptured by wear on the machine surface.

3. The method of repairing a machine surface according to claim 2, wherein the machine surface has dimples of varying depths and the polymeric pouches are placed inside the dimples.

4. The method of repairing a machine surface according to claim 1, wherein a repair agent package including at least one of catalysts, oxidation promoters, and oxidation reduction agents is used to control tribochemical reactions to guide nanoparticle-surface reactions to build up the repair layer.

5. The method of repairing a machine surface according to claim 1, wherein the nanoparticles are applied to the machine surface via lubricating fluid of a machine.

6. The method of repairing a machine surface according to claim 5, wherein repair of the machine surface is initiated when the nanoparticles enter a damaged area of the machine surface.

7. The method of repairing a machine surface according to claim 5, wherein a predetermined amount of the nanoparticles is injected from a reservoir into the lubricating fluid.

8. The method of repairing a machine surface according to claim 1, wherein the repair layer is harder than a substrate material of the machine surface.

9. The method of repairing a machine surface according to claim 1, wherein the repair layer includes an alloy formed during the repair.

10. The method of repairing a machine surface according to claim 1, further comprising:

monitoring sensors to obtain sensor data of at least one of vibration signatures. temperatures, and friction forces of the machine surface;

identifying potential damage to the machine surface based on the sensor data; and

initiating the step of applying the nanoparticles to the machine surface when potential damage to the machine surface is identified.

11. The method of repairing a machine surface according to claim 10, wherein the nanoparticles are encapsulated in polymeric pouches and the nanoparticles are applied to the machine surface when the polymeric pouches are ruptured by wear on the machine surface.

12. The method of repairing a machine surface according to claim 11, wherein the machine surface has dimples of varying depths and the polymeric pouches are placed inside the dimples.

13. The method of repairing a machine surface according to claim 10, wherein a repair agent package including at least one of catalysts, oxidation promoters, and oxidation reduction agents is used to control tribochemical reactions to guide nanoparticle-surface reactions to build up the repair layer.

14. The method of repairing a machine surface according to claim 10, wherein the nanoparticles are applied to the machine surface via lubricating fluid of a machine.

15. The method of repairing a machine surface according to claim 14, wherein repair of the machine surface is initiated when the nanoparticles enter a damaged area of the machine surface.

16. The method of repairing a machine surface according to claim 14, wherein a predetermined amount of the nanoparticles is injected from a reservoir into the lubricating fluid.

17. The method of repairing a machine surface according to claim 10, wherein the repair layer is harder than a substrate material of the machine surface.

18. The method of repairing a machine surface according to claim 10, wherein the repair layer includes an alloy formed during the repair.

19. A self-repairing machine, comprising:

a machine surface subject to wear;

sensors that obtain sensor data of at least one of vibration signatures, temperatures, and friction forces of the machine surface; and

a reservoir containing nanoparticles coated with an organic monolayer having adjustable bonding strength;

wherein potential damage to the machine surface is determined based on the sensor data, a predetermined amount of the nanoparticles is automatically applied to the machine surface from the reservoir based on a determination of potential damage to the machine surface, and the organic monolayer wears away from the nanoparticles under shear stresses and the nanoparticles adhere to the machine surface to form a repaired surface including a repair layer.

20. The self-repairing machine according to claim 19, wherein the nanoparticles are encapsulated in polymeric pouches and the nanoparticles are applied to the machine surface when the polymeric pouches are ruptured by wear on the machine surface.