Prospects for the micro arc oxidation technologies use to improve the reliability of mining equipment
Перспективы использования технологий микродугового оксидирования для повышения надежности оборудования горнопромышленных предприятий
Sabirova L.B. Toshov J.B. Koptleuov K.K.
2025North Caucasian Institute of Mining and Metallurgy, State Technological University
Sustainable Development of Mountain Territories
2025#17Issue 2952 - 964 pp.
Introduction. This study investigates the application of micro-arc oxidation (MAO) technology to enhance the durability, wear resistance, and energy efficiency of compressor equipment used in mining enterprises. The intensive operating conditions of underground mining–characterized by high humidity, dust, cyclic loads, and limited access for maintenance–accelerate wear of friction pairs and reduce equipment reliability. Conventional strengthening methods such as anodizing, thermal spraying, or nitride coatings provide only partial improvements and often suffer from adhesion issues or limited thermal stability. This research introduces MAO as a promising surface treatment for aluminum alloys in compressor systems, aiming to combine lightweight construction with ceramic-like protective layers to achieve longer service life and reduced operating costs. Methods. The methodology included a multi-stage experimental program comprising the formation of oxide coatings on Al–Mg–Si alloy samples, microstructural and mechanical characterization, tribological tests, and integration of treated components into a prototype piston compressor. Coating thickness was controlled by varying treatment time from 10 to 60 minutes, yielding layers between 30 and 150 μm. Hardness was measured by Vickers micro-indentation, while porosity was analyzed via scanning electron microscopy. Tribological behavior was evaluated under sliding conditions using a pin-on-disk configuration, and thermal stability was assessed at elevated temperatures up to 200 °C. Finally, the coated components were assembled into a working compressor unit, and its performance, thermal regime, and energy consumption were compared with baseline machines of similar size. Results. The results demonstrate that MAO coatings increased surface hardness from 130 HV in the base alloy to 1320–1500 HV, achieving more than a tenfold improvement. The coefficient of friction decreased from 0.42–0.45 to 0.11–0.14, with further reduction to 0.08 after fine polishing, while wear resistance improved by a factor of 6–7. In compressor operation, the prototype with MAO-treated parts delivered 232–238 L/min at 8 bar with power consumption of 1.05–1.1 kW, compared to 200–210 L/min and 1.25–1.3 kW for conventional analogues. This corresponds to an energy reduction of 15–18% and an efficiency increase from 61% to 72%. Thermal measurements revealed a 40–50 °C decrease in piston and cylinder temperatures, which correlated with significantly extended component lifetime. Long-term testing confirmed that service life can increase by 2.5–3 times, reducing maintenance frequency and downtime. Conclusions. The findings confirm that micro-arc oxidation offers a robust and efficient solution for enhancing the operational reliability of compressor systems in mining environments. Compared to traditional strengthening methods, MAO provides thicker and harder coatings with superior adhesion and thermal stability, ensuring stable performance under harsh working conditions. The demonstrated reduction in energy consumption and wear directly translates into lower operating costs, improved equipment availability, and increased safety of mining operations. These results establish MAO as a practical technology for both the design of new compressors and the modernization of existing equipment, offering tangible technical and economic benefits for industrial applications.
aluminum alloys , compressor equipment , durability , energy consumption , friction coefficient , micro arc oxidation , mining enterprises , operational reliability , thermal conditions , wear resistance
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K.I. Satbayev Kazakh National Research Technical University, 22, Satpayeva str., Almaty, 050000, Kazakhstan
Tashkent state technical University named after Islam Karimov, 2, Universitetskaya St., Tashkent, 100174, Uzbekistan
K.I. Satbayev Kazakh National Research Technical University
Tashkent state technical University named after Islam Karimov
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Книга Публикация научной статьи Волощук 2026 Book Publication of a scientific article 2026