White Etching Cracking—Simulation in Bearing Rig and Bench Tests

White etching cracking (WEC) is a contact fatigue bearing failure commonly observed in wind turbine applications. It can lead to fatigue lifetimes more than an order of magnitude shorter than expected lifetimes. Though various mechanical and chemical factors have shown direct or indirect impacts of on WEC failure, the correlations between these factors are yet to be fully understood. The critical intersection among various lubricant- and non-lubricant-related parameters and their influence on hydrogen diffusion and WEC formation are discussed in this article. Experimental results are shown under diverse operating conditions and contact configurations using three test rigs. This study confirms that the mechanical properties of a rolling contact and lubrication parameters alone cannot predict WEC failure. The formation of a tribofilm and accumulation of atomic hydrogen below the contact surface can be essential to explain WEC events. Higher hydrogen concentration in the WEC zone depends on contact area size, the presence of metal-containing additives in lubricants, and higher frictional energy dissipation. Finally, a mechanism of WEC failure has been proposed that intersects the overlap of hydrogen and subsurface shear stress.     

Understanding the composition and low friction tribofilm formation/removal in boundary lubrication

The thickness of a tribofilm formed from additives in a lubricant is determined by the nature of a dynamic process which involves film formation and film removal. In this work, the removal rate of tribofilms is studied using a distinctive testing procedure. Tribofilms are produced using a pin-on-reciprocating plate tribometer with lubricants comprising a combination of base oil (PAO6), zinc dialkyldithiophosphate (ZDDP) and molybdenum dialkyldithiocarbamate (MoDTC) additives. In some tests the same lubricant is used throughout the test to assess the formation of the tribofilm. However, an important aspect of the study is the measurement of the tenacity of the tribofilm and to do this the lubricant was changed after a tribofilm had formed, to a lubricant free from additives. Tribofilms (fully developed and partially removed) have been chemically characterised using energy dispersive X-ray analysis (EDX). Qualitative and quantitative information regarding the tenacity of the low friction tribofilms is obtained. Surface analyses have shown that there is a distinct link between chemical composition of the tribofilms formed and their tenacity. The low friction tribofilm formed from the lubricant with ZDDP and MoDTC was shown to be more durable than the one formed from the lubricant with only MoDTC. The mechanism of how the ZDDP tribofilm provides this durability is discussed.     

含超细颗粒固液二相流对PSZ陶瓷与钢摩擦磨损特性的影响

在往复式摩擦磨损试验机上研究了含超细颗粒固液二相流对部分稳定二氧化锆（ＰＳＺ）陶瓷与ＧＣｒ１５钢滑劝副的摩擦磨损性能的影响。选择９０＾＃机械油和ＱＣ３０汽机油为基础油,分别加入五种超细固体颗粒,配制出不同浓度的２０种油样,分别在１６０１７０和１００℃温度下进行试验。结果表明：超细固体颗粒添加剂的用量、试验温度和基础油都影响陶与钢滑动副的摩擦磨损性能。对超细颗粒添加剂的润滑机理进行了初步探讨。     

WEC Formation in Rolling Bearings under Mixed Friction: Influences and “Friction Energy Accumulation” as Indicator

White etching cracks (WEC) can lead to premature rolling contact fatigue. Possible drivers of WEC can be mixed friction, sliding between rolling elements and raceways, electrical current, critical additives, and water-contaminated lubricant. With respect to WEC failures induced by sliding between rolling elements and raceways under mixed friction, an approach is presented that can explain the experimentally observed failure characteristics of cylindrical roller thrust bearings. Variants of the bearing were tested using a WEC-critical lubricant. The tests showed that not only the contact pressure and sliding between rolling elements and raceways but also the lubrication conditions (specific film thickness) and the frequency of the contact load cycles have an influence on WEC life. These influences are reflected best by a newly introduced characteristic parameter termed friction energy accumulation. As far as WEC failures induced by sliding under mixed friction are concerned the friction energy accumulation could be used for a comparative assessment of the WEC risk of arbitrary rolling bearing applications. A link between the friction energy accumulation and the absorption of hydrogen is discussed and can provide further explanations for the susceptibility of bearing components to WEC formation.     

X‐ray absorption near‐edge structure analysis of tribofilms generated by highly efficient,friction‐reducing additive in water–polyglycol–glycol lubricant

The development of environment‐friendly lubricant additives can make a valuable contribution to addressing human health and energy problems. In the present work, the compound ammonium tetrathiomolybdate was synthesised and used as a highly efficient, friction‐reducing additive in water–polyglycol–glycol lubricants. Its tribological properties were tested by a four‐ball machine, and the composition of the tribofilm was identified by X‐ray absorption near‐edge structure (XANES) spectroscopy. The tribological test results indicated that the additive cannot only reduce the friction coefficient value, but can also shorten the rubbing time needed to produce a ‘stable friction coefficient value’. The XANES results showed that the tribofilm is mainly composed of an adsorbed layer and a tribochemical layer; the formation of sulphate and molybdenum trioxide in the tribofilm on the metal wear surface is responsible for the excellent anti‐friction performances of the additive. Copyright © 2009 John Wiley & Sons, Ltd.     

In situ Investigation of the Growth of a Tribofilm Consisting of NaYF4 Fluorescent Nanoparticles

Tribofilms play a vital role in protecting lubricated surfaces in mechanical systems in motion. To date, understanding tribofilms has been mostly based on ex situ analysis. This research investigates the kinetics of a tribofilm formed on a pair of bearing steels (E52100). Strategically selected illuminative nanoparticles of NaYF₄ were added to a base oil in order to enable their tracking. Electrical conductivity was monitored during sliding that was found to be linked to the state of the interface and the tribofilm. Further characterization identified tribochemical reaction products of Y₂O₃ that exhibited superior tribological performance. In comparison with mineral oil as the base lubricant, the addition of NaYF₄ resulted in a reduction in wear of 82%. This work discovered three stages in tribofilm formation: running in, reactive, and growth. Interestingly, the formation of a tribofilm was dominated more by frictional force than applied load. This is significant because we can now use alternative strategies to generate quality tribofilms.     

Model of scuffing based on the vulnerability of an elastohydrodynamic oil film to chemical degradation catalyzed by the contacting surfaces

A model of scuffing is developed based on the premise that metallic surfaces can catalyze degradation of the lubricant film in situ. A failure mechanism for elastohydrodynamic films based on rapid decomposition of mineral and synthetic oils involving chemical reaction between entrapped oil and the containing surfaces is proposed. It is suggested that this destruction of the elastohydrodynamic oil film allows adhesion between nascent metal of opposing surfaces in the contact which in turn causes scuffing. Suppression of scuffing by the application of coatings that do not catalyze the oil decomposition and by the action of some lubricant additives which may block the catalytic effect of metallic surfaces is discussed. Effect of solid lubricant films and contaminant layers on scuffing is also described.     

Sorption of Lubricant Additives by Porous Plastic Retainer Materials

Sorption of additives present in lubricating oils by porous plastic retainer materials was studied by liquid chromatographic experiments. Liquid chromatography columns were packed with finely shredded porous cotton-phenolic and polyimide ball bearing retainer materials. Small aliquots of nonpolar hydrocarbon oils (purified by molecular distillation and prepared to contain additives of various polarities) were individually eluted through, the columns with n-hexane. The eluate from each of the columns was evaporated, and the residues were analyzed for additive content. Atomic absorption and computer-controlled electron-impact mass spectrometry of the eluted samples provided evidence of retention of the lubricant additives in the column. The degree of depletion of additives from the oil samples appears to be a function of the polarities of both the retainer matrix and the additive molecules, and the hydrogen bonding or dipole-dipole interaction resulting therefrom.     

Influence of Dispersant and ZDDP on Soot Wear

Diesel engines and gasoline direct injection (GDI) engines both produce soot due to incomplete combustion of the fuel and some enters the lubricant where it accumulates between drain intervals, promoting wear of rubbing engine components. Currently the most favoured mechanism for this wear is that the anti-wear additives present in engine oils, primarily zinc dialkyldithiophosphates (ZDDPs), react very rapidly with rubbing surfaces to form relatively soft reaction products. These are easily abraded by soot, resulting in a corrosive-abrasive wear mechanism. This study has explored the impact of engine oil dispersant additives on this type of wear using combinations of dispersant, ZDDP and carbon black, a soot surrogate. It has been found that both the concentration and type of dispersant are critical in influencing wear. With most dispersants studied, wear becomes very high over an intermediate dispersant concentration range of ca 0.1–0.4 wt% N, with both lower and higher dispersant levels showing much less wear. However a few dispersants appear able to suppress high wear by ZDDP and carbon black over the whole concentration range. A series of experiments have been carried out to determine the origin of this behaviour and it is believed that high levels of dispersant, and, for a few dispersants, all concentration levels, protect the iron sulphide tribofilm initially formed by ZDDP from abrasion by carbon black.     

Tribochemistry of silicon and oxygen doped,hydrogenated Diamond-like Carbon in fully-formulated oil against low additive oil

Diamond-like Carbon (DLC) coatings are increasingly used to reduce wear and lower friction in many applications. Doped DLCs are being produced with the goal of further enhancing the friction and wear profile as well as increasing the coating reliability.Silicon is often incorporated into DLC as it is known to affect the sp²/sp³ ratio which in turn can affect the hardness of the film. It can also improve adhesion of the DLC coating to the substrate and lower internal stress.In this study, investigations into the wear behaviour, tribochemistry and oil-formulation dependence of Si, O-doped DLC (Si-DLC) were conducted. The oxidative stability of Si-DLC was also examined.Silicon-doped DLC is able to form a protective tribofilm when a fully-formulated lubricant is used. The tribofilm is composed of S, P, Ca and Zn which are widely recognised as being important to wear reduction.A mechanism of wear repression facilitated by oil additives is proposed.     

Antiwear Tribofilm Formation on Steel Surfaces Lubricated With Gear Oil Containing Borate,Phosphorus, and Sulfur Additives

The formation of antiwear tribofilms plays a critical role in the longevity of automotive gears. The focus of this experimental study was on the lubrication efficacy of gear oils with different contents of borate-, phosphorus-, and sulfur-containing additives leading to the formation of protective tribofilms. Experiments were performed with AISI 52100 steel balls sliding against AISI 52100 steel disks in baths of different oils at ambient (～32 °C) and elevated (～100 °C) temperatures under load and speed conditions favoring sliding in the boundary lubrication regime. Friction coefficient responses accompanied by electrical contact voltage measurements provided real-time information about the formation and durability of the antiwear tribofilms. The wear resistance of the tribochemical films was quantified by wear rate data obtained from surface profilometry measurements of wear tracks on the disk specimens and sliding tests performed at ambient temperatures after the formation of the tribofilms during elevated-temperature sliding. Results indicate a strong dependence of tribofilm formation on temperature and type of additives. The slightly lower friction and higher wear resistance obtained at elevated temperatures with blended oils is attributed to the increased chemical reactivity of additives containing borate, phosphorus, and sulfur, leading to the formation of durable tribofilms. Relatively higher wear resistance and faster tribofilm formation were obtained with the borate-enriched gear oil formulations.     

Reactivity of Triphenyl Phosphorothionate in Lubricant Oil Solution

Investigating the thermo-oxidative reactivity of anti-wear additives in lubricant oil solution at high temperature can significantly contribute to an understanding of the mechanism of thermal film and tribofilm formation on metal surfaces. In this study, the reactivity of triphenyl phosphorothionate (TPPT) in lubricant oil solution at high temperature (423 and 473 K) has been studied by Fourier transform infrared spectroscopy (FT-IR) and nuclear magnetic resonance (NMR) spectroscopy. The results show that the TPPT molecule was highly thermally stable and did not completely decompose in oil solution even upon heating at 423 K for 168 h and at 473 K for 72 h. The degradation of the TPPT molecule, which turned out to be a first-order reaction, started taking place after 6 h at both temperatures, leading to the breakage of the P=S bond with the formation of triphenyl phosphate. During these heating experiments, no oil-insoluble compounds were detected. The oxidation of the base oil as a result of the prolonged heating demonstrated that the TPPT molecule did not effectively act as oxidation inhibitor.     

Tribological Behavior of Deagglomerated Active Inorganic Nanoparticles for Advanced Lubrication

The tribological behavior of novel, deagglomerated, and active molybdenum disulfide (MoS₂) nanoparticles as additives in paraffin oil is presented. In a novel approach, the MoS₂ nanoparticles were activated by their intercalation with organic molecules, particularly triglycerides (canola oil) and lecithin (source of phosphorus). A four-ball tribological test setup was used to measure the wear scar diameter, the coefficient of friction, and the extreme pressure properties of such formulated paraffin oils. The results showed significant influence of this uniquely designed MoS₂ nanostructured additive on the coefficient of friction (0.07), the wear scar diameter, and the extreme pressure (315 kg) properties of the paraffin oil. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), and energy dispersive x-ray spectroscopy (EDS) were also used for investigating size, the surface morphology, and the elemental composition of the nanoengineered lubricant. The characterization revealed a particle size less than 100 nm and the elemental composition analysis of the wear track showed the presence of Mo, S, and P in the tribofilm, explaining the observed improvements in the tribological properties.     

抗磨添加剂对不同服役阶段润滑油摩擦学性能的影响

采用黏度测试仪测定新油及3种不同服役阶段润滑油的黏度,采用UMT-II摩擦磨损试验机考察其摩擦学性能,并同时考察3种在用润滑油添加抗磨添加剂后的摩擦学性能。研究结果表明:润滑油的黏度随着运行里程数的增加呈现先降后增的趋势;随润滑油运行里程数的增加,润滑油的摩擦因数增大,导致试验钢球的磨损量也增加;抗磨添加剂对不同服役阶段的润滑油的抗磨性能影响程度不同,在磨合磨损期和正常磨损期,加入抗磨添加剂后并不能改善润滑油的抗磨性能,而在异常磨损期,抗磨添加剂的加入可较好地改善润滑油的抗磨性能。     

Friction modifiers in engine and gear oils

Reducing friction is an important target for any lubricant oil formulator. There are several ways, such as utilisation of multi‐grade oils with low viscosity at low temperature, or use of friction modifiers, to reduce friction in automotive engines and transmissions and thus save fuel. A good means to obtain an energy‐saving lubricant is by the addition of a friction‐reducing additive in a high‐range multigrade oil. This paper presents some considerations on the action mechanism of friction modifiers and the results obtained in engine and gear oils with two new nitrogen‐, sulphur‐, and boron‐containing additives.     

The effect of water on the acid-base properties of new and used IC engine lubricating oils

The absolute values of total base number (TBN) were determined for several sets of both fresh and used engine oil samples. Basic and acidic compounds from these oils have been extracted into water, 7% sea water and ethanol-water (1:1, v/v) mixtures. The extracts have been determined by potentiometric titration as pH extracts, TBN (water extract) and alkalinity. The oil formulations are not resistant to the presence of water but basic additives in fresh oil are more resistant than those for used oils. The percentage of TBN extractable into water significantly increases with service life. The presence of significant amounts of water in lubricating oil is serious and should form part of any lubricant condition monitoring system. The case is argued for both the use of dehydration canisters in oil systems and for the development of a new method of water content determination for used formulated lubricating oils which is quick, accurate and suitable for automated condition monitoring systems. The pH of aqueous extracts for condition monitoring of lubricating oils is shown to be only meaningful for TBN values of 2 or less.     

Influence of oil temperature on gear failures

Typical gear failures like wear, scuffing, micropitting and pitting are influenced by the oil temperature in the lubrication system. High temperatures lead to low viscosities and thus thin lubricant films in the gear mesh with generally detrimental influence on failure performance. On the other hand, for gear oils with additives higher temperatures correspond with higher chemical activity and, at least in some cases, with better failure performance of the lubricant. Last, but not least, at very high temperatures even metallurgical changes have been found with a reduction in material endurance limits. Examples for the influence of oil temperature on gear failure modes, as well as their introduction into load carrying capacity calculation methods are shown. With this background, the often-applied practice of increasing the severity of a gear oil test method by increasing the oil temperature has to be revised. Adequate solutions are discussed.     

Threshold Maps for Inclusion-Initiated Micro-Cracks and White Etching Areas in Bearing Steel: The Role of Impact Loading and Surface Sliding

Wind turbine gearbox (WTG) bearings can fail prematurely, significantly affecting wind turbine operational availability and the cost of energy production. The current most commonly accepted theory of failure mechanism is that the bearing subsurface is weakened by white etching crack (WEC) networks that eventually lead to the flaking away of material from the bearing surface. Subsurface damage due to rolling contact fatigue (RCF) is thought to be the main cause of premature failure, resulting from the initiation of micro-cracks, often at non-metallic inclusions or other material defects, which then propagate to the bearing surface. This study proposes a hypothesis that impact loading together with high levels of surface traction and contact pressure are important factors contributing to the initiation of micro-cracks and white etching areas (WEAs) at non-metallic inclusions which may lead to the formation of WEC networks. Both repeated impact and twin-disc RCF tests were designed to investigate inclusion-initiated micro-cracks and WEAs at subsurface in order to test this hypothesis. This led to the recreation of inclusion-initiated micro-cracks and WEAs in tested specimens, similar to the subsurface damage observed at inclusions in failed WTG bearing raceways. Tests were carried out to determine threshold levels of contact pressure, surface traction, and impact loading required for the formation of inclusion-initiated micro-cracks and WEAs.     

Correlation Studies of WS 2 Fullerene-Like Nanoparticles Enhanced Tribofilms: A Scanning Electron Microscopy Analysis

The beneficiary effects of tungsten disulphide (WS₂) inorganic fullerene-like nanoparticles (IFLNPs) in the lubrication industry were shown in recent years. However, their successful incorporation into lubricants (oils, greases) is not straightforward. In practice, the lubricant contains several components for different purposes, e.g. reducing the oxidization of the oil (antioxidant), minimizing the wear rate (anti-wear additive), dispersants, etc. These additives can contain chemically active compounds, which under the lubrication process (where locally extreme conditions can develop: high pressure and flash temperatures) can change the chemistry in the contact zone and block the beneficial effects of the inorganic nanoparticles. In this investigation, poly-alpha-olefin (PAO) is being used as base oil in which the WS₂ nanoparticles and different additives are mixed. A ball-on-disc sliding test revealed that certain additives inhibit the nanoparticles to reduce friction (less than 5 % decrease in friction coefficient), while in other cases, the friction reduction was above 50 %. The comparison is being made between PAO + additive and PAO + additive + IFLNPs. Scanning electron microscope and energy dispersive X-ray spectroscopy were used to investigate the elemental composition of the tribofilms formed on the wear marks. Further analysis was made in order to reveal correlations between elemental compositions of the tribofilms and external parameters such as the friction coefficient and wear rate. For instance, a strong correlation between tungsten content of the tribofilm and the friction coefficient was found.     

Static and dynamic analysis of elastohydrodynamic elliptical journal bearing with micropolar lubricant

In this paper the effect of deformation of the bearing liner on the static and dynamic performance characteristics of an elliptical (two-lobe) journal bearing operating with micropolar lubricant is presented. Lubricating oil containing additives and contaminants is modeled as micropolar fluid. A generalized form of Reynold's equation is derived from the fluid flow and diffusion equations. Finite element technique is used to solve the modified Reynold's equation governing the flow of micropolar lubricant in the clearance space of the journal bearing and the three-dimensional elasticity equations governing the displacement field in the bearing shell. The static and dynamic characteristics of the bearing are computed for a wide range of deformation coefficient which takes into accountant the flexibility of bearing liner by treating operating lubricant as (i) Newtonian and (ii) micropolar. The computed results show that the increasing volume concentration of additives and mass transfer of additives produce significant changes on the performance characteristics.