Technology
5 Key Stages of XADO Revitalization Technology Explained
Revitalization — “bringing back to life”
The word revitalization (Latin: vita — life) literally means “bringing back to life”. XADO revitalization technology is based on unique physical and chemical processes that occur during friction under specific conditions. These processes allow worn metal surfaces to be restored, strengthened, and protected through the formation of a new ceramic‑metal (CERMET) coating.
When a mechanism is operating, stress forms on friction surfaces. Under high load, excessive thermal energy is released, accelerating wear and gradually destroying metal components. However, when a revitalizant is introduced into the friction zone, this destructive energy is converted into constructive energy. Instead of breaking down the surface, the revitalizant uses the excess energy to build a new protective layer. In other words, the energy of destruction becomes the energy of creation.
If you want to explore revitalization products, visit our Engine Additives Collection.
For a deeper understanding of friction, wear, and lubrication, see this UK engineering reference:
Friction, Wear and Lubrication - Discover Engineering
1. Wear and tear of the operating surface
Metal surfaces naturally wear over time. A defect can begin with something as small as a scratch or chip caused by dust, dirt, or microscopic metal particles. These defects become zones of extremely high surface activity. In these areas, metal atoms have uncompensated connections, making them easier to loosen and tear away under load. As a result, the metal begins to chip, and wear accelerates.
Left untreated, these micro‑defects grow, leading to increased friction, reduced efficiency, and eventual failure of the component.
2. Start of the revitalization process
The revitalizant reaches the friction surface together with the lubricant. It begins working precisely in the areas of the heaviest wear, where excess thermal energy is present and metal atoms have the highest number of uncompensated connections. These active zones act like magnets, attracting and holding the revitalizant particles.
Once captured, the revitalizant begins forming the initial structure of the new protective layer. This process only occurs where wear is present, ensuring that revitalization is targeted and efficient.
3. New coating formation
Within minutes of the revitalization process beginning, a ceramic‑metal patch forms in the area where the scratch or defect existed. The zone of high activity disappears as the revitalizant stabilises the energy processes on the surface. Once the defect is filled and the surface is restored, the growth of the ceramic‑metal coating naturally stops.
This self‑limiting behaviour ensures that the coating forms only where needed, preserving the original geometry of the part while restoring worn areas.
4. Completion of the surface modification
As the revitalization process continues, the protective layer diffuses into the metal, forming an extremely strong gradient ceramic‑metal coating. This CERMET layer has unique operational properties, including high durability, resistance to corrosion, and exceptional smoothness.
The result is a restored surface that performs better than the original factory finish.
5. Revitalization results and benefits
The potential of revitalization has transformed modern approaches to vehicle and machinery maintenance. XADO products offer a high‑tech yet simple method to reverse wear and restore mechanical components without disassembly.
After revitalization, a new coating forms on the friction surfaces, restoring geometry and improving performance. This coating has exceptional properties: microhardness of 650–750 kg/mm², high corrosion resistance, and a surface roughness as low as Ra 0.06 microns. As a result, parts can last 2–4 times longer after revitalization.
The revitalized mechanism operates more smoothly, efficiently, and reliably — often better than when it was new.
Repair and restoration of assemblies
A new metalloceramic coating forms on friction pairs, increasing their weight and volume while restoring their original geometry. In some cases, the restored layer can reach up to 1.5 mm in thickness. This restoration occurs during normal operation, ensuring an ideal fit between friction surfaces. As a result, power output increases, mechanical accuracy improves, and noise and vibration are reduced.
Resource saving and reduced wear
The new coating has exceptional durability and corrosion resistance. It prevents further metal loss, maintains an ideal friction surface, and significantly increases the reliability and lifespan of mechanical assemblies.
Power and energy efficiency
The metalloceramic coating has an extremely low friction coefficient. After treatment, friction surfaces operate more efficiently, resulting in energy savings of up to 30%. This improves fuel economy and reduces mechanical losses.
Environmental benefits
Reduced friction and improved combustion efficiency lead to lower emissions. Revitalized mechanisms release fewer harmful exhaust substances (CO, CH, NOx), contributing to cleaner operation and reduced environmental impact.
Demonstration of the revitalization process
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BEFORE |
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AFTER |
A real surface of a part before and after revitalization
After 500 km (300 miles) of operation, the defect has been completely removed. A perfectly smoothed ceramic‑metal coating has formed on the surface of the part.How does it work? – Demonstration experiment
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The rolling path of a bearing is intentionally damaged using an engraving cutter. These defects are made larger than those that typically occur during normal operation, ensuring the test is rigorous. Such defects act as stress concentrators and can lead to part failure. -
The bearing is filled with XADO Repairing Grease, designed for heavily worn units (up to 80% wear). -
The bearing’s rolling path initially shows a rough factory surface with deep grinding marks. A point defect (a crater) is created for testing, measuring 0.5 mm in diameter and up to 0.7 mm deep.
The bearing filled with grease is exposed to an 8000 N load at 1,000 rpm for 15 minutes. During operation, revitalization occurs — the defect is eliminated as a ceramic‑metal coating forms on the friction surface.
After 15 minutes, the surface is smooth and glassy. The original grinding marks have disappeared. The crater’s edges show buildup resembling snow drifts, demonstrating how the defect is filled from the edges inward.