Sustainable production of critical components for the oil and gas industry

This research addresses the need for sustainable manufacturing and quality assurance of high-load components in the oil and gas sector within the frameworks of Industry 4.0 and Industry 5.0. The primary objective was to optimize the finishing treatment of the functional internal surfaces of NB 32.02.102-04 cylinder liners for NB-32 drilling pumps by replacing conventional energy-intensive finishing processes with more resource-efficient alternatives. A progressive technological route was proposed in which traditional grinding and honing operations were replaced by pressure-based finishing using Vibratory-Centrifugal Hardening (VCH) and hard-alloy surface modification. A methodology was developed to analyze technological inheritability by evaluating the transfer and transformation of surface roughness parameters throughout the manufacturing route, from rough boring to final plastic deformation finishing (PDF). Volumetric vibratory equipment was adapted specifically to treat the hard-to-access internal surfaces of these critical components. The experimental results demonstrated a substantial improvement in surface roughness characteristics. The arithmetic mean deviation of the profile (Ra) decreased nearly tenfold, from 6.12 to 0.63 μm, while the ten-point height of irregularities (Rz) decreased by approximately 17-fold, reaching 1.38 μm. In addition, the load-bearing capacity of the surface was improved, as indicated by a 1.7-fold increase in the relative bearing length (tm). At the same time, the spacing parameters RS and RSm decreased by more than fourfold. The analysis of technological inheritability identified VCH as a critical technological barrier that effectively transforms the inherited surface characteristics and promotes the formation of a surface state with improved functional properties. The developed technology aligns with the principles of sustainable manufacturing. It supports the United Nations Sustainable Development Goals (SDGs) 7, 9, 12, and 13 by eliminating the use of potentially hazardous cutting fluids and abrasive materials, reducing energy demand, and minimizing material waste. The findings demonstrate the potential of integrating vibratory-centrifugal hardening into the manufacturing route of NB 32.02.102-04 cylinder liners as an environmentally responsible finishing strategy. At the same time, further research is required to establish its effects on wear resistance, fatigue strength, and the long-term reliability of critical industrial components.