What are the manufacturing materials and process requirements of the micro-oil air compressor?

The manufacturing materials and process requirements of the micro-oil air compressor are as follows:

1. Core Manufacturing Materials

1. main frame and moving parts
   • steel: Crankshafts, connecting rods, crosshead pins and other key moving parts are usually forged with 45# steel to ensure high strength and wear resistance. For example, the crankshaft needs to be extruded and forged by external force, and its mechanical properties are better than castings and it is not easy to deform.
   • cast iron some parts (such as cylinder heads) may be cast iron, but modern designs prefer carbon steel plates or forgings, such as SA516-70 grade plates, to improve corrosion resistance and structural strength.
2. Sealing and lubrication related parts
   • wear resistant alloy: Oil scraper ring, stuffing box sealing ring, etc. are made of high-quality wear-resistant alloy cast iron (such as HT200) or cast tin bronze (such as ZQSn6-6-3) to reduce friction and extend life.
   • Sealing material: The valve sealing element may use special plastic (such as PEEK or Vespel), and the spring is made of stainless steel or Inconel alloy to ensure high temperature resistance and corrosion resistance.
3. Gas contact parts
   • stainless Steel if the cylinder head needs to be resistant to corrosion, it may be made of 304 or 316 stainless steel (such as type SA240); the diaphragm is usually made of high tensile strength stainless steel (such as 301 or 316).
   • special alloy in harsh environments (such as highly corrosive gases), Monel (nickel alloy) or Alloy20 materials may be used.
4. Auxiliary parts
   • copper pipe: Used for refrigerant flow channel to improve heat dissipation efficiency.
   • Plastic: The housing or non-critical parts may be made of lightweight plastic to reduce cost and weight.

2. key process requirements

1. blank manufacturing
   • forging and casting: Moving parts are preferentially forged (such as crankshafts) to improve mechanical properties; parts such as cylinder heads may be machined or forged from plates, selected according to strength requirements.
   • Machining allowance control: The blank needs to reserve enough machining allowance (usually 4-5mm) to ensure the subsequent finishing accuracy. For example, after the crankshaft is forged, it needs to meet the dimensional tolerance requirements through rough turning, fine turning, grinding and other processes.
2. Machining and Assembly
   • high precision machining: Critical components (e. g. cylinders, pistons) need to be finished to ensure surface finish and dimensional accuracy to reduce the risk of leakage.
   • Sealing treatment: The gas seal and oil seal shall be completely separated (such as triple labyrinth seal) to prevent lubricating oil from entering the compression chamber. For example, dry oil-free screw technology reduces friction through a PTFE composite coating without the need for lubricating oil.
   • assembly accuracy: The centering and clearance shall be strictly controlled during component assembly to avoid running vibration or wear. For example, the coupling needs to be balanced to ensure smooth operation.
3. Lubrication and cooling system
   • lubricating oil circulation: Micro-oil compressors need to filter lubricating oil through post-treatment equipment such as oil and gas separators and oil filters to ensure that the oil content of compressed air is less than 3-5ppm (high-end models can be reduced to less than 1ppm).
   • Cooling Design: Oil cooler and air cooler need to dissipate heat efficiently to prevent performance degradation caused by high temperature. For example, a temperature control valve may be set in the oil circuit to automatically adjust the oil temperature to the best range.
4. Quality inspection and testing
   • non-destructive testing key components (such as crankshaft and cylinder head) shall be subject to liquid penetration test or X-ray inspection to check defects such as cracks and pores.
   • Performance Test: Before delivery, full pressure operation test is required to measure the actual flow (usually inert gas to simulate process gas), and check the leakage of gas side, hydraulic side and cooling cycle.

Material and Process Optimization for 3. Special Scenarios

• chemical Industry: If the compressed gas contains corrosive components (such as ammonia), the cylinder head and valve body shall be made of stainless steel or special alloy, and separator and liquid repellent shall be added to prevent corrosion of condensate.
• Food and pharmaceutical industry: It is required to meet the ISO 8573-1 Class 0 oil-free standard, adopt water-lubricated oil-free screw technology, completely eliminate lubricating oil pollution, and pass the certification of SGS and other institutions.
• High Altitude Environment: The compression ratio and cooling system design need to be adjusted to prevent the compression efficiency from decreasing or overheating due to thin air.