Biobased dry‐film metalworking lubricants

Metalworking lubricants must allow the manufacture of acceptable products at competitive cost without causing harm to operators or the environment. One way of attaining such a goal is through the use of biobased raw materials in lubricant formaulations. Biobased materials are generally non‐toxic, easily biodegradable, and abundantly available from renewable agricultural sources. However, successful application of biobased marterials in lubrication requires a thorough understanding of the tribochemical properties of these agricultural products. Recent studies have shown that biobased lubricants comprising starch and vegetable oils have promising lubrication properties. This paper discusses investigations into the effect of film thickness on the friction properties of dry‐film lubricants formulated from starch‐soybean oil composites.     

Film‐forming additives ‐ direct and indirect ways to reduce friction

This paper reviews the current understanding of lubricated contacts and the origins of friction in terms of the Stribeck curve. It discusses the various ways that lubricant additives can modify friction in thin‐film lubricated contacts, examining both the nature and properties of the films formed by these additives, as revealed by film thickness measurements, and their consequent effect on the Stribeck friction curve.     

Soot–additive interactions in engine oils

Soot is known to cause engine wear. In this work, we focus on how engine oil formulation affects soot‐related wear, and how the lubricant‐derived anti‐wear film changes when soot is present. Friction and wear experiments of fully and partially formulated diesel engine oils (containing basestock, dispersants and viscosity modifiers) are conducted with a ball‐on‐disk rig in the presence of carbon black (CB) as a soot surrogate. The friction coefficient was largely unaffected by CB dispersed in the oils, but electrically insulating film formation, an indication of the formation of anti‐wear films, was decreased. Wear on the disk was found to either remain the same or decrease when CB was present, depending on the oil formulation. An examination of the lubricant‐derived films using Raman and Auger electron spectroscopies found that the presence of more abundant amorphous carbon and lesser amounts of anti‐wear film components on the surface was associated with higher wear. Copyright © 2009 John Wiley & Sons, Ltd.     

Literature review of OCP viscosity modifiers

Olefin copolymers and terpolymers (OCPs) are used as viscosity modifiers in a large proportion of the European and world multigrade oil market. The polymer properties of the basic ethylene propylene polymers are critical to the physical characteristics of the final lubricant and its engine performance. The important parameters are discussed. Ethylene propylene polymers intended for use in other industrial applications should be checked thoroughly to avoid potential field problems. Modifications of these speciality OCPs to dispersant polymers enhance diesel and dispersant lubricant properties, enabling the most severe lubricant performance requirements to be met. The paper also reviews developments reported in the literature on the production and handling of the products together with their application, particularly with reference to their effect on low temperature properties, engine cleanliness, wear and fuel economy of the lubricant.     

Effects of Ethanol Contamination on Friction and Elastohydrodynamic Film Thickness of Engine Oils

The use of ethanol as engine fuel has increased for environmental reasons, both in flex-fuel engines and as increasing amounts of ethanol blended with gasoline in conventional engines. This article describes an investigation into the effects of ethanol contamination of lubricants during engine use with ethanol fuel. To facilitate this, a new technique was developed to measure small amounts of ethanol in lubricants. Elastohydrodynamic film thickness measurements and Stribeck curves were obtained for Group I base and formulated oils containing small added amounts of ethanol. The effect of the water present in hydrated ethanol was evaluated by carrying out tests using both hydrated and anhydrous ethanol. Measurements were also carried out using a Group II base oil with added ethanol. These measurements showed that in the low entrainment speed region, where the elastohydrodynamic film is very thin so that boundary lubrication prevails, the addition of ethanol produced a boundary film, which was not present for the base oils. By contrast, the addition of ethanol to formulated oil reduced film thickness in all lubrication regimes. The friction tests showed friction reduction due to addition of ethanol to the base oil, in particular at low speeds. For the formulated oil, ethanol reduced friction at high speeds, which was associated with a reduction in the viscosity of the lubricant, but at low speeds, ethanol reduced the formation of a boundary layer, increasing friction. The presence of water in hydrated ethanol did not significantly change the film thickness and friction when compared with anhydrous ethanol.     

Lubricity characteristics of ethyl hexyl esters of mono‐, Di‐, and triethenoic acids

Ethyl hexyl esters of oleic, linoleic, and linolenic acids were synthesised and thermally polymerised to obtain products with viscosities in the range of hydrocarbon lubricants at 100°C (11–22 cSt). Molecular weight, elemental analysis, IR, ¹³C NMR, and intrinsic viscosity data showed that most of these derivatives are mixtures of monomers, dimers, and trimers and have linear and cyclic products with predominantly trans characteristics. The lubricity characteristics were determined on a friction and wear tester under conditions of thick‐film lubrication. A comparison was made with hydrocracked hydrocarbon lubricants of comparable viscosities at 100°C and comparable viscosity indices. It is inferred that all the esters maintained relatively thicker surface films and much lower friction coefficients than the hydrocarbon oils. The wear‐scar data show that the antiwear characteristics of polymerised ethyl hexyl oleate and linoleate are only slightly inferior to those of the hydrocarbon oils, but at higher temperatures their antiwear characteristics rapidly deteriorate while the friction coefficients markedly increase and become comparable to those of hydrocarbon oils. These studies are being undertaken with a view to selecting and modifying vegetable oils containing mixtures of fatty acids for obtaining esters of outstanding friction, wear, and film‐forming characteristics.     

A tribological investigation of lubricant effects on bearing friction and fuel economy for passenger car engines and heavy duty diesel engines

Rising fuel costs and the need to conserve fossil fuel have led to increased interest in the role of lubricants in improving fuel economy. Crankshaft bearings can account for up to 40% of engine friction. Lubricant formulations can provide a beneficial reduction in engine friction, thus improving fuel economy. A unique journal bearing test rig has been developed to evaluate lubricants under transient and steady‐state conditions for passenger car engines and heavy duty diesel engines. The rig can measure bearing friction over a wide temperature, speed and load range. The rig uses production components and can be operated so as to produce the bearing pressures, lambda ratio and shear rates experienced by lubricants in fired engines. The properties of a range of lubricants of varying viscometrics, including Newtonian, non‐Newtonian and fully formulated oils have been evaluated. Significant differences due to formulation have been observed. The results of the study have been compared to fuel economy data generated from fired engines with the same lubricants as those tested in the journal bearing rig. Copyright © 2006 John Wiley & Sons, Ltd.     

齿轮滑油对轿车齿轮传动效率和燃油经济性的影响

1．首先应当考虑轿车的油耗只和摩擦学有关,其中影响最明显的是润滑油。2．采用测量润滑方法只能阐述机械损失,因此,燃油经济性实现改善的可能性受到了限制,特别当考虑齿轮高效率的时候,3．在评价粘性对燃油消耗的影响时,所谓粘性必须考虑有效粘性,对这非牛顿油是非常重要的,4．按SAE粘度梯度降低齿轮油粘度,将可使燃油消耗在高温时降低0．2－1．5％,低温时降低0．4－2．5％。5．在齿轮油中应用摩擦改良时,燃油消耗的实际降低在1．0－6．0％之间。6．减少摩阻50％的基础上,考虑不同的传动过程,燃油消耗降低为其他齿轮油1．0－5．1％之间。7．汽车齿轮试验,使燃油消耗改善大小顺序按为其他齿轮油1％。8．测量结果确定计算估价的原则。     

The influence of soot and dispersant on ZDDP film thickness and friction

The effect of dispersed soot in engine oils is an increasingly important issue in terms of both engine durability and fuel efficiency. Using carbon black as a soot analogue, a study has been carried out to investigate the main factors that determine the impact of soot on friction and ZDDP film formation in formulated oils. It has been found that dispersed carbon black can rapidly remove ZDDP reaction films by abrasion. However, this removal can be prevented or limited by the choice of an optimal dispersant additive.     

Mixtures of vegetable oils and di‐2‐ethylhexyl‐sebacate as lubricants

Lubricants based on vegetable oils are growing in popularity in various applications. Environmentally friendly, vegetable oils and their derivatives constitute alternatives to mineral‐based lubricants. Soybean oil, sunflower oil and rapeseed oil have better viscosity indices than mineral oils and even some synthetic oils, are biodegradable and have low production costs. However, vegetable oils have disadvantages, such as poor thermo‐oxidative stability due to the carbon–carbon double bonds and poor low‐temperature properties, which limit their use as lubricant base stocks. This study describes new base‐stock oils obtained from mixture of vegetable oils and di‐2‐ethylhexyl‐sebacate synthetic oil, which become lubricants when additives are introduced. These mixtures offer a large range of kinematic viscosities, while their pour points are under −33°C and their flash points over 240°C. The copper strip corrosion test result is 1a. The diameters of wear scars measured under four‐ball testing (40dyn) are less than 1mm. A differential scanning calorimetry study and a thermo‐gravimetric study under a nitrogen atmosphere for the mixed oils are reported. In the former study two‐endothermic processes were observed between −15°C and −50°C. In the thermo‐gravimetric analysis curve the weight loss is specific for each vegetable and synthetic oil component. From these studies a higher thermal stability was observed for vegetable oils than for ester oils, and it was concluded that the mixtures of vegetable and synthetic oils of diester type are physically homogeneous mixtures. The low production cost of lubricants based on vegetable oils makes them attractive alternatives for mineral oil based lubricants. Overall the mixtures of vegetable and ester oils can be competitive base oils for environmentally friendly lubricants. Copyright © 2006 John Wiley & Sons, Ltd.     

Large‐scale specimen testing on friction and wear of pure and internally lubricated cast polyamides

Due to the casting process for nylons, their composition can easily be modified to cover a wide range of mechanical properties and applications, especially as large wear surfaces in, for example, crane guidances. Presently, selection tests for working conditions up to 40MPa are presented on pure Na‐catalysed polyamides, oil‐filled polyamides with homogeneous oil dispersions and holes in the surface containing oil lubricant and two types of thermoplastic solid‐lubricated polyamides. Pure polyamides are, however, prone to high and unstable sliding at pressures as low as 10MPa with brittle fracture and lumpy transfer. Oil lubrication is not able to remove the sliding instabilities as oil supply to the sliding interface is controlled by migration effects that are restricted by deformation and thermal softening or melting of the polyamide matrix. Although friction and wear are lower and more stable for samples with oil supplied through lubricating holes, additional running‐in phenomena are attributed to a relatively thick transfer film that is brittle and easily peels off. A continuous thick molten film or island‐like deposition occurs on the polyamide surface. Solid lubricants are able to stabilize friction and lower wear down to the formation of a thin and coherent transfer film. However, increasing the amount of lubricants induces lower mechanical properties and higher deformation of the test samples. The differences in transfer behaviour are discussed with reference to optical microscopy and calculations of bulk and flash temperatures. Copyright © 2006 John Wiley & Sons, Ltd.     

Lubricant viscosity and viscosity improver additive effects on diesel fuel economy

This work verifies the impact of lubricant viscosity and viscosity improver additives on diesel fuel economy. Eight lubricants were tested in a single-cylinder, four-stroke, direct injection diesel engine mounted on a dynamometer, under different load and speed conditions. Engine friction power was also investigated through Willans’ line. The results demonstrate that fuel economy obtained from multigrade viscosity oils is higher than that obtained from monograde viscosity oils. A linear relationship was obtained between the high temperature high shear viscosity and specific fuel consumption. The lubricant which provided lower fuel consumption also required lower friction power.     

Synthesis and tribological behaviour of phosphorus—nitrogen‐modified rape seed oils as biodegradable lubricant additives

Two types of phosphorus—nitrogen‐modified rape seed oils as biodegradable lubricant additives were synthesised and characterised by infrared spectroscopy. Their tribological properties in rape seed oil and in mineral oil were evaluated in a four‐ball tester. The morphologies of the worn surfaces were analysed by scanning electron microscopy. The results show that the modified rape seed oil additives improve the load‐carrying capacity and the antiwear and friction‐reducing properties of rape seed oil more than they do those of mineral oil. The inferred mechanism of lubrication is that a high‐strength adsorption film and/or tribochemical reaction film forms on the rubbing surfaces, due to the carrier effect of long‐chain rape seed oil molecules and to the high reaction activities of phosphorus and nitrogen and their synergism.     

EP/AW performance evaluation of some zinc alkyl/dialkyl/alkylaryl‐dithiocarbamates in four‐ball tests

Tribochemistry, the chemistry of interacting surfaces under the influence of a lubricant, helps in the appropriate selection of suitable lubricant additives for specific uses. Modern lubricants are usually formulated from a range of petroleum base oils or synthetic fluids incorporating a variety of chemical additives for performance enhancement. Extreme‐pressure (EP) and anti‐wear (AW) additives are used extensively in lubricants for hypoid gears and metal cutting and forming operations to reduce wear, modify friction, and prevent scuffing of moving metallic parts. The present paper includes the synthesis and the evaluation of the tribological properties of 0.5% (w/v) solutions of some zinc bis‐(alkyl/dialkyl/alkylaryldithiocarbamates) in paraffin oil using 12.7 mm diameter steel bearing ball specimens in four‐ball tests. All the synthesised zinc dithiocarbamate additives in general, and zinc bis‐(morpholinodithio‐carbamate) (A₄) in particular, exhibited good AW, EP, and friction‐reducing properties. Additive A₄ especially gave low values of wear‐scar diameter and coefficient of friction at higher loads and higher values of load wear index and flash temperature parameter during EP tests (ASTM D 2783) and afforded lower values of wear‐scar diameter in a one‐hour wear test (ASTM D 2266–67). The surface topography of the wear‐scar matrix of the used ball specimens was investigated by scanning electron microscopy.     

Viscosity and working efficiency analysis of soybean oil based bio-lubricants

This article presents significant data about viscosity and working efficiency analysis for developing the soybean oil based bio-lubricants. A suitable viscosity or viscosity index (VI) plays a very important role in a lubricant, which can avoid collision and rubbing between components of mechanical devices in work as well as optimize working efficiency of a machine. In general, low friction between devices can increase working efficiency of a machine, but low viscosity of a lubricant will easily cause collision and rubbing between components of mechanical devices in work. A too viscous lubricant also requires a large amount of energy to move, but a too thin lubricant will easily cause rubbed devices and increased friction. To replace the mineral oils and syntholubes, the soybean oil is recently become one of the most actively studied oils due to its eco-friendly organic property and lower cost. This work used mixtures of the original soybean oil, the epoxidized soybean oil, and the hydrogenated soybean oil as the base oils. Applications are focused on developing engine bio-lubricants. The results show that the epoxidized soybean oil has extremely large viscosity in comparison with the engine lubricants as well as the original soybean oil, whereas the hydrogenated soybean oil is clearly opposite. This viscosity analysis offers good informations to fit viscosity of the engine lubricants by mixing the three soybean oils as base oils.     

Piston deposit control using metal‐free additives

Engines can be damaged in many ways: the principal oil‐related problems are due to deposit formation and viscosity increase. A first step in minimising the consequences of oil degradation is to reduce the formation of sludge and deposits. This can be accomplished by the judicious use of metal‐free (ashless) anti‐oxidants. Detergent/dispersant additives play a critical role in extending lubricant life by cleaning up deposits and keeping them in solution, and by neutralising acids formed during the combustion process. Several different types of antioxidants that can successfully eliminate precursors that lead to deposit formation and viscosity increase in oils in both gasoline and diesel engines have been identified. A novel, ashless, multifunctional additive that confers thermo‐oxidative stability and friction modification to engine lubricants is described here.     

Formation,structure, and properties of lubricant-derived antiwear films

In recent years, surface analytical methods that determine structure have been combined with methods that measure elemental composition and oxidation states, to yield an improved understanding of lubricant-derived tribofilms. Methods assessing the mechanical properties of thin films have also been applied to tribofilms with thicknesses of the order of nanometres. These methods, in combination with chemical and physical studies of bulk lubricant systems and assessments of lubricant behaviour in tribological environments, have made it possible to describe comprehensively film forming mechanisms, structures and tribological properties. This paper outlines the initial results of such an attempt, focusing on zinc dialkyl dithiophosphates and overbased detergents in model systems and engine oils.     

Thermo‐oxidative stability of new‐generation base oils

Thermo‐oxidation of base oils is the primary cause of lubricant degradation and engine failure during use. Degradation is mainly due to high‐temperature oxidation and thermal decomposition near the piston ring zone, forming oxygenated compounds that polymerise to form high‐molecular‐weight insoluble deposits. New‐generation base oils are found to be more stable towards oxidation and deposit formation due to the absence of aromatics and polynaphthenes. However, compatibility with antioxidants and other additives is now of greater concern because of the poor solvency of these oils. With the increase in the purity of the oil, sometimes the oxidation performance is poor in comparison to group I oils, mainly due to the removal of sulphur compounds, which act as natural antioxidants. Thermal techniques, such as differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA), are emerging as fast and accurate methods for determining the thermo‐oxidative stability of base oils and their additive blends, making it possible to measure the oxidation induction time, incipient oxidation temperature, and deposit‐forming tendency. The objective of this work is to evaluate the thermo‐oxidative stability of new‐generation group II/III base oils without antioxidant additives, using DSC and TGA. The kinetics of base oil oxidative degradation are studied using different heating rates. The data obtained from thermal techniques are correlated with the micro‐oxidation data obtained from the Penn State Micro‐Oxidation (PSMO) test. The response of a typical antioxidant additive, zinc dialkyldithiophosphate, towards oxidative degradation of base oils has also been studied.     

汽油机油配方对节能发动机试验的影响

介绍了汽油机油节能发动机试验的发展状况,讨论了油品配方对节能性能的影响。发动机试验表明,基础油、粘度指数改进剂及添加剂都是影响汽油机油节能性能的因素,在不同的发动机试验中基础油、粘度指数改进剂、抗氧抗腐剂、摩擦改性剂、清净剂、分散剂的影响存在不同的表现形式,在配方设计中要根据具体的发动机试验来确定。     

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.