lubricant options and challenges - io.uaelit-oil.io.ua/files/0001/15/00011562.pdf · lubricant...
TRANSCRIPT
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 3
Understanding the Fuel & Lubricants Road to the OEM
Lubricant options & challenges – Transmissions and Axle Session 1Slide 4
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 6
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 7
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 8
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 9
GO106-002
Base Oil70 - 95%
Pour Point Depressant0 - 2%
Viscosity Modifier0 - 40%
Additive Package5 - 30%
Typical Formulation (Weight %)Typical Lubricant Overview
Lubricant options & challenges – Transmissions and Axle Session 1Slide 10
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 12
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 13
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 14
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 15
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 16
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 17
Typical Oil Film Thickness
0
20
40
60
80
100
Human Hair Hydrodynamic Elastohydrodynamic Boundary
Lubricant options & challenges – Transmissions and Axle Session 1Slide 19
The Stribeck CurveC
oeffi
cien
t of F
rictio
n
0.150
0.001
Viscosity * SpeedLoad
Boundary Mixed HydrodynamicEHD
Lubricant options & challenges – Transmissions and Axle Session 1Slide 20
The Stribeck CurveC
oeffi
cien
t of F
rictio
n
0.150
0.001
Viscosity * SpeedLoad
Boundary Mixed HydrodynamicEHD
Lubricant options & challenges – Transmissions and Axle Session 1Slide 21
The Stribeck CurveC
oeffi
cien
t of F
rictio
n
0.150
0.001
Viscosity * SpeedLoad
Boundary Mixed HydrodynamicEHD
Piston Rings
Piston Skirt
Valve Train
Engine Bearings
Gears
Lubricant options & challenges – Transmissions and Axle Session 1Slide 23
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 24
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 25
• Break-in - Removal of Gases and Water
• Physical or Chemical adsorption
Reacts with metal surfaces to from a solid protective reaction layer
• 4-Step Process
Antiwear Mechanism 抗磨机理
Lubricant options & challenges – Transmissions and Axle Session 1Slide 26
• Break-in - Removal of Gases and Water
• Physical or Chemical adsorption
• Additive – Surface reaction
Reacts with metal surfaces to from a solid protective reaction layer
• 4-Step Process
Anti-wear Mechanism
Lubricant options & challenges – Transmissions and Axle Session 1Slide 27
• Break-in - Removal of Gases and Water
• Physical or Chemical adsorption
• Additive - Surface reaction
• Reaction Layer Growth
Reacts with metal surfaces to from a solid protective reaction layer
• 4-Step Process
Anti-wear Mechanism
Lubricant options & challenges – Transmissions and Axle Session 1Slide 28
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 30
EP MechanismReacts with metal surfaces to from a sacrificial reaction layer
4-Step Process
• Break-in - Removal of Gases and Water
• Physical or Chemical adsorption
• Additive – Surface reaction
Gas
es
Wat
er
Gas
es
Wat
er
Gas
es
Wat
er
Lubricant options & challenges – Transmissions and Axle Session 1Slide 31
EP Interactions with Surfaces
Iron sulfide (or chloride) reaction layers
Rough Surface Smoother surface
4th Step – Sacrificial (controlled) wear of asperities
Lubricant options & challenges – Transmissions and Axle Session 1Slide 32
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 34
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 35
% 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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 36
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)
Lubricant options & challenges – Transmissions and Axle Session 1Slide 38
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?
Lubricant options & challenges – Transmissions and Axle Session 1Slide 39
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?
Lubricant options & challenges – Transmissions and Axle Session 1Slide 40
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?
Lubricant options & challenges – Transmissions and Axle Session 1Slide 41
HOMOPOLYMER RANDOM COPOLYMER
ALTERNATING COPOLYMER
BLOCK COPOLYMERGRAFT COPOLYMER
© The Lubrizol Corporation 2012. All rights reserved.41
Polymer Compositions
Lubricant options & challenges – Transmissions and Axle Session 1Slide 42
COMB-LIKE BRANCHED POLYMER
CROSSLINKED NETWORK
LINEAR POLYMER - FUNCTIONALIZED POLYMER
STAR-SHAPED POLYMER
© The Lubrizol Corporation 2012. All rights reserved.42
Polymer Architecture
Lubricant options & challenges – Transmissions and Axle Session 1Slide 43
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
© The Lubrizol Corporation 2012. All rights reserved.43
Viscosity Index (VI)
Lubricant options & challenges – Transmissions and Axle Session 1Slide 44
© The Lubrizol Corporation 2012. All rights reserved.44
Viscosity Index (VI)
Temperature / °C
Low VI
High VI
10040
Log
(Vis
cosi
ty)
Cold start Normal use
Lubricant options & challenges – Transmissions and Axle Session 1Slide 45
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
© The Lubrizol Corporation 2012. All rights reserved.45
Viscosity Index (VI)
Lubricant options & challenges – Transmissions and Axle Session 1Slide 46
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
© The Lubrizol Corporation 2012. All rights reserved.46
Shear Stability - Reversible
Lubricant options & challenges – Transmissions and Axle Session 1Slide 47
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
►
►
►
►
© The Lubrizol Corporation 2012. All rights reserved.47
Shear Stability - Irreversible
Lubricant options & challenges – Transmissions and Axle Session 1Slide 48
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
© The Lubrizol Corporation 2012. All rights reserved.48
Shear Stability - Irreversible
Lubricant options & challenges – Transmissions and Axle Session 1Slide 49
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)
Lubricant options & challenges – Transmissions and Axle Session 1Slide 50
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 52
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 53
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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 54
• 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
Lubricant options & challenges – Transmissions and Axle Session 1Slide 55
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.