lubricant options and challenges - io.uaelit-oil.io.ua/files/0001/15/00011562.pdf · lubricant...

Axle CentersSlide 0

Lubricant Options and Challenges

Lubricant Options and Challenges

Simon EvansAutomotive Gear Oil Technical Manager

Lubrizol Ltd.

Simon Evans

Lubrizol

Mr. Simon Evans is currently a driveline automotive gear oil technical manager for Lubrizol, based in Hazelwood, UK. He is responsible for liaising with OEMs globally on their future lubricant requirements, developing additives to meet these needs and implementing these newly designed technologies into the marketplace. Simon joined Lubrizol as an automotive technician in 1987 before moving into field testing, and then into his current role in 2000. Whilst at Lubrizol Simon has obtained both engineering and business qualifications (MBA)

in 1999.

INSTRUCTOR BIO

The Lubrizol Corporation

The Lubrizol Corporation is an innovative specialty chemical company focused on improving the quality and performance

of our customers’ products in the global transportation, industrial and consumer markets. While we serve many different

markets, similar technologies drive their growth. Our focus is on surface active chemistries, rheology modifi ers, and

polymer and fi lm technologies. Our customers know and value our ability at solving their problems and our ability to

provide them with differentiable performance claims that they use in marketing their products.

Chairman, President and Chief Executive Offi cer: James L. Hambrick

2010 Revenues: $5.4 billion

Headquarters: Cleveland, Ohio USA

Number of Employees Worldwide: 6,900

Lubrizol Additives

The Lubrizol legacy was built upon the unprecedented pioneering of lubricant additives designed to improve the

performance of fuels and lubricants for transportation and industry. Our engine oil additives offer an expansive range of

applications, from cars to construction equipment, motorcycles to marine vessels. We also have a full range of gasoline,

diesel and biofuel additives that can improve the performance of our customers’ fuels. As the only additive company with a

product line for all on- and off-road driveline applications, Lubrizol provides advanced technologies for use in transmission

fl uids, gear oil and farm tractor fl uids. In addition, we offer performance additive packages and components for a wide

range of industrial lubrication applications.

Lubrizol Advanced Materials

With an impressive history extending back to the 1870s (formerly BFGoodrich Performance Materials), Lubrizol Advanced

Materials is a leading global producer of advanced specialty polymers, polymer-based additives and chemical additives.

Used in everyday consumer and industrial applications, our additives and ingredients can be found in everything you

touch, from personal care products to pharmaceuticals, plastics technology to performance coatings. Businesses include:

Estane® Engineered Polymers; Noveon® Consumer Specialties; Performance Coatings; and TempRite® Engineered

Polymers

Research, Manufacturing and Sales

The Lubrizol Corporation is geographically diverse, with an extensive global manufacturing, supply chain, technical and

commercial infrastructure. Lubrizol owns and operates manufacturing facilities in 17 countries, as well as sales and

technical offi ces around the world.

Contact Information

For additional information about The Lubrizol Corporation, visit our website at

www.lubrizol.com.

Fact Sheet

The Lubrizol Corporation29400 Lakeland Boulevard, Wickliffe, Ohio 44092

Telephone: 440.943.4200

www.lubrizol.com

© The Lubrizol Corporation 2011

110219 A4

Driveline Additives

Lubrizol is the only additive company with a product line that covers all on- and off-road driveline applications. With our unpar-

alleled breadth and depth of knowledge, superior technical facilities and talented people, we continue to introduce innovative

transmission fluid, gear oil and farm tractor fluid technologies to ensure equipment runs better and lasts longer.

Products and Applications

Lubrizol’s automatic transmission fluid additive technology is used in transmissions for passenger cars, commercial

vehicles, off-road vehicles and non-transmission applications, such as power steering, small hydraulic pumps and farm

equipment. Our technologies control sludge and varnish; prevent rust and corrosion; prevent fluid leakage; and protect gears,

clutch plates, bushings and other metal parts.

Lubrizol’s gear oil additive technology has applications in passenger cars, trucks and heavy equipment. Lubrizol’s

Anglamol® gear oil additive packages focus on friction reduction, heat removal and extreme pressure anti wear additives to

prevent wear, pitting, spalling, scoring, scuffing and other types of distress that can result in equipment failure and downtime.

Lubrizol’s off-highway lubricant additives are used in fluids that lubricate transmissions, final drives, wet brakes,

transmission clutches and hydraulic systems, typically from a common fluid reservoir on the vehicle. Off-highway lubricants

are used in both on and off-highway commercial transmissions, high-pressure hydraulic systems, and construction, mining,

agricultural and forestry equipment.

Research, Manufacturing and Sales

The Lubrizol Corporation is geographically diverse, with an extensive global manufacturing, supply chain, technical and

commercial infrastructure. Lubrizol owns and operates manufacturing facilities in 17 countries, as well as sales and technical

offices around the world.

Contact Information

For additional information about our driveline additives, visit our Web site at

www.lubrizol.com.

Fact Sheet

The Lubrizol Corporation29400 Lakeland Boulevard, Wickliffe, Ohio 44092

Telephone: 440.943.4200

www.lubrizol.com

© The Lubrizol Corporation 2010

100275B

Lubricant options & challenges – Transmissions and Axle Session 1Slide 2

• This session has been prepared with the objective of providing detailed information on the subject of lubricants, and axle technology

• Key learning objectives are:-– Gain appreciation of the complexity for developing fluids including viscosity

modifiers– Understand more about what a lubricant contains– Understand the performance differences between lubricants – Gain knowledge of the components used in formulating dedicated farm

tractor driveline products– Validation of the role that other parts of formulations play– To review some of the testing methodologies used in the development of

farm tractor products

Objective


Understanding the Fuel & Lubricants Road to the OEM


Lubricant Operating Model

OEM

Oil Company

Additive Supplier

• Fluid Needs / Future Hardware designs• Final Fluid validation testing

• Test Development• Problem solving• Optimized Fluid Development

• Supply Logistics• Problem Solving• Base Oil Technology

• Additive Technology Development• Lubricant Testing

Lubricants and Additives


What is a Lubricant?

• Lubricant Overview– Performance Requirements– Lubricant Performance– Friction Modifiers– Anti-wear Additives– EP Additives– Base Oils– Viscosity Modifiers & Pour Point Depressants– Others


Hardware Performance Requirements

Primary Requirements for a Lubricant– Deliver the right balance of friction compatibility– Extreme pressure protection for load carrying– Bearing life– Thermal stability– Transfer heat– Seal compatibility– Prevent corrosion– Prevent foaming


Functions of a Lubricant

• Lubrication• Reduces friction and wear by introducing a lubricating film

between moving parts• Cooling

• Helps dissipate heat away from the critical parts of the equipment

• Cleaning and suspending or dispersing• Facilitates smooth operation of equipment by removing and

suspending products, such as carbon, sludge, and varnish• Protection

• Prevents metal damage due to oxidation and corrosion


GO106-002

Base Oil70 - 95%

Pour Point Depressant0 - 2%

Viscosity Modifier0 - 40%

Additive Package5 - 30%

Typical Formulation (Weight %)Typical Lubricant Overview


Lubricant Performance Demands

MTF Axle Oil ATF Engine OilExtreme Pressure ++ +++ + +Anti-wear ++ ++ + ++Dispersancy + + ++ +++Detergency ++ + + +++Oxidation Inhibition ++ ++ ++ ++Corrosion Inhibition +++ ++ +++ +Friction +++ + +++ +

Unique performance typically provided by sulfur and phosphorus chemistry

Major differences in needs between manual transmission and axle applications


LUBRICATION REGIMES


Lubrication Regimes

Hydrodynamic• Full Fluid Film• Friction Low and Wear theoretically zero• Viscosity Important

Mixed• Part Fluid Film • Part Surface contact• Viscosity and Chemistry Important

Boundary• Surface on Surface• Chemistry Important

Elastohydrodynamic

•Full Fluid Film•Non Conforming surfaces•Viscosity Important

Incr

easi

ng

Spe

ed

Incr

easi

ng

Load


Hydrodynamic Lubrication

Main Feature• Full Fluid Film• Friction Low and Wear theoretically

zero

Operating Conditions• Normal Loads• Normal Speeds

Examples• Plain Bearings

• Big End Bearings• Main Bearings

Factors Affecting Performance• Viscosity• Viscosity Index• Shear rate


Mixed Lubrication

Main Feature• Load carried on

• Fluid Film• Boundary Film

Operating Conditions• Higher Loads• Slower Speeds

Examples• Valve stems• Rocker Arms• Piston ring / Liner at TDC

Factors Affecting Performance• Viscosity• Viscosity Index• Shear rate• Additive Chemistry


Boundary Lubrication

Main Feature• Load carried by surface contact• Performance depends on boundary film • Antiwear and EP additives important

Operating Conditions• High Loads• Slow Speeds

Examples• Gears

Factors Affecting Performance• Additive Chemistry•Chemical Reactivity•Film Strength


Elastohydrodynamic Lubrication

Main Feature• Load carried on Fluid Film

Operating Conditions• Non-conforming Contacts• Elastic Deformation of components

Examples• Ball Bearings• Roller Bearings• Cam / Follower

Factors Affecting Performance• Viscosity• Viscosity Index• Pressure Coefficient of Viscosity


Typical Oil Film Thickness

0

20

40

60

80

100

Human Hair Hydrodynamic Elastohydrodynamic Boundary


THE STRIBECK CURVE


The Stribeck CurveC

oeffi

cien

t of F

rictio

n

0.150

0.001

Viscosity * SpeedLoad

Boundary Mixed HydrodynamicEHD


The Stribeck CurveC

oeffi

cien

t of F

rictio

n

0.150

0.001




The Stribeck CurveC

oeffi

cien

t of F

rictio

n

0.150

0.001



Piston Rings

Piston Skirt

Valve Train

Engine Bearings

Gears

Anti-wear Additives


Anti-wear Additives

• They modify the surface of components: • Reduce Wear• Form chemical layers on the surface

of metal components• Require higher temps and / or loads to

become activated

Chemical Reaction


Anti-wear Mechanism

Reacts with metal surfaces to from a solid protective reaction layer

• 4-Step ProcessG

ases

Wat

er

Gas

es

Wat

er

Gas

es

Wat

er

• Break-in - Removal of Gases and Water



• Physical or Chemical adsorption


• 4-Step Process

Antiwear Mechanism 抗磨机理




• Additive – Surface reaction


• 4-Step Process

Anti-wear Mechanism




• Additive - Surface reaction

• Reaction Layer Growth


• 4-Step Process

Anti-wear Mechanism


Anti-wear Mechanism

• Reaction with metal surfaces to form a solid protective reaction layer

• Typically delivered by sulfur and phosphorous-containing chemistry in the formulation

• Prevents metal surface wear

GO106-036

Anti-wear filmcontainingsulfur andphosphoruscompounds

Metal Surface

EP Additives


EP MechanismReacts with metal surfaces to from a sacrificial reaction layer

4-Step Process



• Additive – Surface reaction

Gas

es

Wat

er

Gas

es

Wat

er

Gas

es

Wat

er


EP Interactions with Surfaces

Iron sulfide (or chloride) reaction layers

Rough Surface Smoother surface

4th Step – Sacrificial (controlled) wear of asperities


Extreme Pressure (EP) Mechanism• Chemical reaction with metal surfaces to form a sacrificial wear layer

• Reaction only occurs under extreme pressure and temperature

• Reaction layer has a lower shear strength than the metal

• Prevents metal-to-metal contact and welding

• Typically delivered by sulfur-containing chemistry in formulation

• EP needs are great in hypoid axles due to high loading and sliding action of gear teeth

Metal Surface

Metal Surface

Base Oils


Base oils are long chain hydrocarbons with good lubricating properties:• Mineral - Products of crude oil refining process• Synthetic - Synthetically made products of chemical reaction

What are base oils?

Base oils• Provide the means for physically separating the mating surfaces of

moving machine parts• Act as a heat transfer agent• Is the carrier or medium for the performance package


% by weightCarbon 83 - 87

Hydrogen 11 - 14

Sulfur 0 - 8

Nitrogen 0 - 1

Oxygen 0.5

Metals 0.02

AltamountUtah USA

Minas Sumatra

BoscanVenezuela

Barrow Island Australia

Arabian light Middle East

SourakhanyCaucasus

Base Oils


Base Oil Groups

Group Comment Advantage Disadvantage

I Broad grouping. Contains some sulfur and aromatic.

Solvency. Good in hot-running diesel type tests. Sulfur can be a natural antioxidant.

Some high sulfur types can be sludge formers. Some low sulfur types can have poor oxidative stability. Consistency of manufacture.

II Contains high saturates with more cycloparaffins compared to paraffins.

Good oxidative stability. Consistency of manufacture.

Poor solvency in hot-running diesel tests

III Contains high saturates and a VI ≥120

Very good oxidative stability. High VI can allow for use of less VM. Usually good low temperature properties.

Can have high cost. Solvency if oil breaks down before the end of test.

IV 100% branch paraffins. Excellent oxidative stability. Excellent low temperature properties.

High cost. Usually oil does not break down before end of test. Sometimes there is a cosmetic haze of additives (poor solvency)

Viscosity Modifiersand Pour Point Depressants


Multigrade Oil Properties

VI2 411-12-03

• Oil soluble polymers which change the viscosity characteristics of the lubricant

• Almost all engine oils and many transmission and hydraulic oils contain VMs

• 2 key properties that affect VM performance are– Viscosity index (VI)– Shear Stability

What is a Viscosity Modifier?


Viscosity modifiers increase viscosity of base oil Increases low temperature viscosity as little as possibleThickening relates to hydrodynamic volume

ViscosityPolymer thickened oil

Normal base oil

►

►

►

Temperature© The Lubrizol Corporation 2012. All rights reserved.39

What is a Viscosity Modifier?


A long chain of repeating monomer units can be called a polymer if an addition of one more monomer unit to this chain would not have an effect on its chemical and physical behavior.

Monomers[Single parts]

Polymers[Many parts]

Reaction

© The Lubrizol Corporation 2012. All rights reserved.40

What is a Polymer?


HOMOPOLYMER RANDOM COPOLYMER

ALTERNATING COPOLYMER

BLOCK COPOLYMERGRAFT COPOLYMER


Polymer Compositions


COMB-LIKE BRANCHED POLYMER

CROSSLINKED NETWORK

LINEAR POLYMER - FUNCTIONALIZED POLYMER

STAR-SHAPED POLYMER


Polymer Architecture


Temperature

Viscosity

Acceptable viscosity range

Base oil

Low VI

High VI

VI (Viscosity index) increases with increasing VM concentration and increasing VM Molecular WeightMarket is driving toward increasingly higher VI fluids for fuel economy and durability

►

►

Higher VI indicates less change in viscosity with temperature


Viscosity Index (VI)




Temperature / °C

Low VI

High VI

10040

Log

(Vis

cosi

ty)

Cold start Normal use


VI = [(L-U)/(L-H)] x 100

Where:L = KV40* of an oil of 0 VI having the same KV100 as the oil whose VI is to be calculated

U = KV40 of the oil whose VI is to be calculated

H = KV40 of an oil of 100 VI having the same KV100 as the oil whose VI is to be calculated

*KV40 is the kinematic viscosity at 40°C

40°C 100°C

0

100

60

20

40

80Vis

cosi

ty in

dex

L

U

H

VI =L – UL – H X 100




Shear stability = ability of a fluid to maintain its viscosity after stress

Viscosity loss at high shear rates due to shear thinning nature of polymers (non-Newtonian behavior)

Viscosity gained back after stress is removed

Reversible shear loss is dependent on:

Concentration of polymer in solution

MW of the polymer chain

Temperature, as it affects molecular motion

►

►

►

►

►

►

►

Low

Low

High

High Viscosity

Shear

Measured by HTHS and CCS


Shear Stability - Reversible


VM oil blend before and after shear

0

1

2

3

4

5

6

7

8

VM VM with shear

KV1

00 /

cSt

VM thickeningBase oil thickening

Initial viscosity

After shear viscosity

Percent Viscosity Loss

= (Initial -After Shear) / Initial x 100

Irreversible decrease in viscosity due to breakdown of the polymer molecule

Affects durability of the fluid

Function of polymer backbone length (Molecular Weight)

Time and temperature dependent

►

►

►

►


Shear Stability - Irreversible


VM oil blend before and after shear

0

1

2

3

4

5

6

7

8

VM VM with shear

KV1

00 /

cSt

VM thickeningBase oil thickening

Initial viscosity

After shear viscosity

Shear Stability Index

= (Init-After) / (Init-BOV) x 100

SSI is “percent thickening loss”

It easily allows for the formulator to calculate the After Shear Viscosity or Percent Shear Loss for a wide variety of blends

Changing the base oil viscosity will not significantly effect SSI

Changing the polymer treat will not significantly effect SSI

►

►

►

►

Base oil viscosity


Shear Stability - Irreversible


Waxes in mineral oils precipitate at lower temperatures forming interlocking crystal networks

Light oils form large, soft crystals

Heavy oils (Bright Stocks) form harder microcrystalline waxes

PPDs change morphology of the crystals by co-crystallization with the waxes

Prevent large interlocking needle-like masses from forming and promote formation of smaller, more rounded free-moving particles

►

►

►

►

►

Wax crystals without PPD Wax crystals with PPD© The Lubrizol Corporation 2012. All rights reserved.49

Pour Point Depressants (PPD)


The Shape of the Curve Is Unique to a Specific PPD/Base Oil System

% wt PPD

Pour Point Temperature

Wax-PPDInteraction

PPD -VM Interaction

How PPDs work

Other Additives and their Functions


Detergents• Chemically combine with solid combustion debris to prevent them from

accumulating as deposits. Neutralizes acids into neutral salts

Dispersants• Function as repelling magnets to prevent particulate contamination in the

oil from agglomerating into larger lumps that settle out as sludge or vanish

Anti-Oxidants• Prevent oxygen in atmosphere from chemically reacting with the oil by

either destroying free radicals or interacting with peroxides to retard oil thickening due to oxidation


Rust & Corrosion Inhibitors• Provide a barrier between the metal surface and the harmful elements,

either by neutralizing acids or forming protective films.

Foam inhibitors• Minimise foaming by decreasing the surface tension of the lubricant, i.e.

the tendency of neighbouring molecules at the surface to stick together as a film. Excessive foaming can result in ineffective lubrication and cause oil oxidation

Friction Modifiers• Modify frictional properties


• To summarise this presentation has provided details on:-– Gaining appreciation of the complexity for developing fluids

including viscosity modifiers– Understanding more about what a lubricant contains– Understanding the performance differences between lubricants – Gaining knowledge of the components used in formulating

dedicated farm tractor driveline products– Validation of the role that other parts of formulations play– Testing methodologies used in the development of farm tractor

products

Summary


Mr. Simon Evans is currently a driveline automotive gear oil technical manager for Lubrizol, based in Hazelwood, UK. He is responsible for liaising with OEMs globally on their future lubricant requirements, developing additives to meet these needs and implementing these newly designed technologies into the marketplace.

Simon joined Lubrizol as an automotive technician in 1987 before moving into field testing, and then into his current role in 2000. Whilst at Lubrizol Simon has obtained both engineering and business qualifications (MBA) in 1999.


Thank you!

lubricant options and challenges - io.uaelit-oil.io.ua/files/0001/15/00011562.pdf · lubricant...

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