case studies
The VICTREX® PEEK™ polymer family of thermoplastic products has helped make important advances in the exploration and production of energy, particularly oil and gas.
A range of applications incorporating VICTREX PEEK polymer have provided longer equipment service life in more severe conditions, including higher temperatures and pressures. It has been instrumental in helping companies achieve higher production rates, reduce downtime, and lower maintenance requirements.
Daido Metal Co., Ltd.: Large bearings designed for hydro-generation applications
The Challenge
Striving to improve load capacity and operating temperature, major bearings manufacturer, Daido Metal Co. Ltd. was interested in developing a large bearing designed for hydro-generation applications that is highly durable and has high slidability qualities.
Traditionally, the material used for high load and high-speed revolution bearings utilized in hydro-generator and similar applications was white metal (an alloy of tin, copper and antimony). However, white metal has been considered difficult to use in miniaturization due to issues related to heat resistance and mechanical strength.
The Solution
Daido adopted VICTREX® PEEK™ polymer — renowned for its high strength, high heat resistance and low friction factor — to the surface of its bearings. In doing so, Daido was able to improve the load capacity by 50% and reduce the friction factor by approximately 30 to 40%. This resulted in the ability to reduce the surface of the bearing by approximately 60% and also increase the operating temperature to 250°C (compared to 125°C for white metal products). In addition, Daido's internal performance testing indicates that bearing life will potentially increase to twice of that of white metal based bearings.
These large bearings have been very well received by heavy electric manufacturers in Japan and throughout the world. Daido plans to aggressively expand to gas and steam generator manufacturers throughout Europe and the USA as well as into the large industrial machine sector with large pumps, compressors, and more.
Daido states, "Ultra-fine bronze beading is sintered on the back of the rear steel plate surface and then the resulting porous intermediary layer of VICTREX PEEK polymer is injected using a proprietary impregnation technique. In this way, the base material (steel) and the sliding surface (VICTREX PEEK polymer) are solidly soldered together." Daido also says, "Oil filters were necessary to facilitate smooth revolution for large revolving machines using white metal based bearings that required oil pressure during initial motion (when revolution begins). However, now that VICTREX PEEK polymer — with its superior sliding qualities — is used in the bearings, such equipment is no longer required. This makes it possible to streamline related equipment and maintenance. In addition, due to the high chemical resistance of VICTREX PEEK polymer, it is also possible to omit the need for bearing insulation."
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