Transcript Basic of Lubricants & lubrication - WordPress.com

The Basics of
Lubricants and lubrication
Hussam Adeni
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Meaning of lubrication
• Friction - is created when there is
relative motion between two surfaces
• Resistance to motion is defined as
friction
• Lubrication is use of a material
between surfaces to reduce friction
• Any material used is called a lubricant
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Methods of lubrication
• Two main methods
• Hydrodynamic lubrication
• Boundary lubrication
• Hydrodynamic lubrication
• Also called complete or full flow
• Occurs when two surfaces are
completed separated by a fluid film
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Methods of lubrication
cont..
• Two main methods
• Hydrodynamic lubrication
• Boundary lubrication
• Boundary lubrication
• Occurs when Hydrodynamic lubrication
fails.
• By adsorption or chemical reaction
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Types of Lubricant - Physical
• Liquid
• Solid
• Semi solid
• Gases
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Types of Lubricant - Physical
• Liquid
• Typical lubricants are liquid/fluids
• Mineral oil or synthetic oils
• Solid
• Graphite, MoS2
• Semi solid
• Greases
• Gases
• Atomised 2 stroke oils
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Typical lubricants - Application
• Engine oils
• Gear Oils
• Turbine Oils
• Hydraulic Oils
• Metal working oils
• Cutting oils
• Forming Oils
• Rust preventives
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Typical lubricants - Application
• Heat Transfer Oils
• Heat Treatment Oils
• Quenching Oils
• Tempering Oils
• Refrigeration Oils
• Rubber Process Oils
• Ink process Oils
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Lubricant - Components
• Base Oils
• Mineral by-products of crude oil refining
process.
• Base oils are polymerized or
synthesized further and called synthetic
• Additives
• Natural
• Synthetic
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Function of a lubricant
• Lubricate - Reduce friction
• Cooling - Heat transfer
• Cleaning - Detergency
• Noise pollution - dampening
• Sealing – prevent leakage
• Protection – prevent wear
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Lubricate – reduce friction
• The effects of friction
• Metal to metal contact
• Leads to wear and tear
• Generates heat
• Results in Power loss
• Lubricant reduces friction by
forming a film
• Reduces ill effect of friction
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Cooling
• When fuel is burnt in an engine
• 33% is useful power
• 33% removed by cooling water
• 33% by lube oil and radiation
• Lube oil removes heat from all areas
and brings it to the engine sump.
• Improper cooling can lead to over
heating, lead to wear, distortion and
failure.
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Cleaning
• Cleans carbon and varnish deposits
• Flushes the entire system removing
•
•
•
•
•
Soot
Deposits
Acids
Wear products
Moisture
• Removes external contaminants dust,
moisture (external)
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Noise reduction
• Reduce noise
• By preventing metal to metal contact
• Dampens noise
• As between camshaft and tappet
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Sealing
• Oil film
• Between piston ring and liner
• Helps in creating a gas tight seal
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Protection
• Protection against acids and
moisture
• Very important to increase life of
component and equipment
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Properties of lubricants
• Kinematic viscosity
• Viscosity index
• Pour Point
• Flash Point
• Total Base Number (TBN)
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Properties of lubricants
• Kinematic viscosity
• Measure of internal resistance to flow
• “Thickness” of fluid (in laymen terms)
• Decreases with increase in temperature
• Important in lubricant selection
• Increase in used oil indicates oxidation
• Specified at 40˚C and 100˚C
• Measured in Centi Stokes (CSt)
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Kinematic Viscosity Recommendations
• Low Viscosity oils used
• High speeds
• Low pressure
• Low temperature
• High Viscosity oils used
• Low speeds
• High pressure
• High temperature
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Properties of lubricants
• Viscosity index
• Measure of fluids change of viscosity
with temperature.
• Empirical number
• Higher the VI lower will be the
change of viscosity with temperature
• Indicator of temperature range of
operations
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Properties of lubricants
• Pour Point
• Lowest temperature at which the fluid
will flow
• Indicates lowest operating
temperature
• Measured in ˚C
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Properties of lubricants
• Flash Point
• Lowest temperature at which the vapor
above the liquid will ignite under flame
• Indicated safe maximum temperature of
operation.
• Indicator of volatility
• Test method - COC and PMCC
• Measured in ˚C
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Properties of lubricants
• Total Base Number (TBN)
• Measured the acid neutralizing
reserve in oil.
• Important for deciding discard of oil
• Decreases due to
• Oxidation of oil
• Water contamination
• Fuel contamination
• Measured in Mg KOH/gm of oil
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Lab Tests - for lubricants
Kinematic viscosity
Viscosity index
Pour Point
Flash Point
Total Base Number
(TBN)
Hussam Adeni
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
D
D
D
D
D
D
445
2250
97
92 (COC)
93 (PMCC)
664
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What are additives
Lubricant additives
classified on their functional capability
Enhance existing property
Suppress undesirable property
Impart new property
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What are additives
– What they do in Engine Oils
Protect metal surfaces
-
(rings, bearings, gears, etc.)
Extend the range of lubricant
applicability
Extend lubricant life
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Surface Protective additives
Anti wear and EP Agent
Corrosion & Rust inhibitor
Detergent
Dispersant
Friction modifier
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Surface Protective additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Anti wear & EP Agent
Reduce friction & wear.
Prevent scoring & seizure
ZDDP, Organic Phosphates, acid
phosphates, organic sulfur and chlorine
compounds etc.
Chemical reaction with metal surface
and forms a film.
Prevents metal-to-metal contact
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Surface Protective additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Corrosion and Rust Inhibitor
Prevent corrosion and rusting of the
metallic parts in contact with lubricant
ZDDP, Metal phenolates, Basic Metal
sulphonates, fatty acid & Amines.
Preferential adsorbtion of polar
constituent on metal surface.
Provide protective film
Neutralize corrosive acids
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Surface Protective additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Detergents
Keep surface free of deposits
Metallo organic compounds of Sodium,
Calcium and Magnesium phenolates
Phosphonates and sulphonates
Chemical reaction with sludge and
varnish percursors to neutralize them
and keep them soluble
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Surface Protective additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Dispersant
Keep insoluble contaminants
dispersed in the lubricant
Alkylsuccinimides, alkylsuccinic esters
and mannich reaction products
Contaminants are bonded by polar
attraction to dispersant molecules.
Prevented from agglomerating
Kept in suspension due to solubility of
dispersant
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Surface Protective additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Friction modifier
Alters coefficient of friction
Organic fatty acids and amides.
Lard Oil, high molecular weight
organic phosphorus.
Phosphoric acid esters
Preferential adsorbtion of surface
active materials
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Performance additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Pour Point Depressant
Enable lubricant to flow at lo
temperature
Alkylated naphthalene
Phenolic polymers, Ploymethacrylates
Maleate/fumerate copolymer esters
Modify wax crystal formation to reduce
interlocking
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Performance additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Seal swell Agent
Swell elastomeric seals, gaskets
Organic phosphates
Aromatic hydro carbons
Chemical reaction with with elastomer
to cause slight swell.
Hussam Adeni
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Performance additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Viscosity modifier
Reduce the rate of viscosity change
with temperature
Polymers and copolymers of olefins,
methacrylates, dienes
Alkylated styrenes.
Polymers expand with increasing
temperatures
This counteract oil thinning
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Performance additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Antifoamant
Prevent lubricant from forming a
persistent foam
Silicone polymers
Organic copolymers
Reduce Surface tension to speed
collapse of foam
Hussam Adeni
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Performance additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Antioxidant
Retard oxidative decomposition
ZDDP,
Hindered phenols, Aromatic Amines,
sulfurized phenols
Decompose peroxides
Terminates free-radical reactions
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Performance additives
- Automotive Lubricants
 Additive type
 Purpose
 Typical
compounds
 Function
Metal deactivator
Reduce catalytic effect of metals on
oxidation rate
Organic complexes containing
nitrogen or sulfur
Amines, sulphides and Phosphates
Forms inactive film on metal surfaces
by complexing with metallic ions
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Lubricant - Nomenclature
and Specifications
Nomenclature
• Crankcase oils - SAE numbers
• Viscosity classification – ISO 3448
• Grease – NLGI Numbers
Performance
• Crankcase oils - Performance levels
• Crankcase oils – OEM Specifications
• US Military – US-MIL-2104
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2000
1500
ISO VG
AGMA
1500
1000
800
600
500
• Viscosity Grade Classification
Systems
400
ISO – Industrial Oils
• cSt @ 40°C
AGMA – Industrial Gear Oils
• cSt @ 40°C
SAE – Engine Oils
•
•
• cSt @100°C
• cP @ -12°C to -55°C
8A
680
8
460
7
5000
3000
3000
2000
6
90
5
1000
40
100
3
30
1000
85W
80W
68
2
46
1
20
500500
400400
300
300
75W
200
200
32
22
10
140
4
30
20
15
5000
150
150
100
80
10000
50
220
200
SAE
Gear
Oils
2000
320
300
cSt @100°C, cP @150°C 60
50
cP @ -10°C to -40°C
40
SAE – Gear Oils
1000
SAE
Engine
Oils
15
10
cSt @ 40C
SUS @ 100F
15W
10W
100
85W&0W
100
60
60
Lubricant - Specifications
• Crankcase oils - SAE numbers
• Crankcase oils - Performance levels
• Crankcase oils – OEM Specifications
• Viscosity classification
• Grease specification
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Major specifying
organizations
• SAE – Society of Automotive Engineers
•
•
•
•
•
(USA)
API - American Petroleum Institute
US Military Specs – US - MIL – 2104 CCMC – European Specification
ISO – International Standard Organization –
ISO 3348
NLGI – National Lubricating Grease Institute
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SAE viscosity grades for
engine oils
Designated
• With corresponding viscosity
• For high temperature application
• Warmer areas/regions
• SAE 20
• SAE 30
• SAE 40
• SAE 10
• SAE 50
• SAE 60
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SAE viscosity grades for
engine oils
Designated
• With corresponding viscosity
• For low temperature application
• Colder areas/regions
• SAE 0 W
• SAE 5 W
• SAE 10 W
• SAE 15 W
• SAE 20 W
• SAE 25 W
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SAE viscosity grades for
Mono grades - Engine Oils
Mono grades are designated
with single SAE number
•
•
•
•
•
SAE 10, 20, 30, 40, 50
SAE 5W,10W, 15W,20W,25W
Can be used either in summer season
or in winter seasons.
Gradual shift to multi grades.
Shift also due to lower oil
consumption by multi grades
Available as Engine oil and Gear Oils
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SAE viscosity grades for
Multi grades - Engine Oils
Multi grades are designated
with two SAE number
Widely in use today
• SAE 10w/30, 15w/30, 25w/50
• SAE 5W/30, 20W/40
• Suitable for use in winter and summer
months or seasons
• Available in Engine oils & Gear oil
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SAE Crankcase Oil - Viscosity
classification – Winter Service
SAE
Viscosity
Grade
Low temp viscosities
High temp viscosities
Max. Temp for Vis. at 100˚C,
Engine cranking
High shear
(cP) 150˚C
Max. cPs at Temp pumping viscosity cSt
of 60,000 cP(˚C)
(˚C)
Min
Max & 106 S-¹
Min
Winter Service
6200@ -35
0W
6200@ -30
5W
7000@ -25
10W
7000@ -20
15W
20W
25W
9500@ -15
13000@ -10
-40
-35
-30
-25
-20
-15
Hussam Adeni
3.8
3.8
4.1
5.6
5.6
9.3
-
--
-
-
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SAE Crankcase Oil - Viscosity
classification – Summer Service
SAE
Viscosity
Grade
Low temp viscosities
High temp viscosities
Max. Temp for Vis. at 100˚C, cSt
Engine
High shear
pumping
(cP) 150˚C &
cranking Max.
viscosity of
Min
Max 106 S-¹ Min
cPs at Temp
60,000 cP(˚C)
(˚C)
Summer Service
-20
-30
-40
-40
-50
-60
-
5.6
<9.3
2.6
-
9.3
12.5
<12.5
<16.3
2.9
3.5
-
12.5
<16.3
3.7
-
16.3
<21.9
3.7
-
21.9
<26.1
3.7
Hussam Adeni
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API Automotive Gasoline Engine
Service Categories – “SA, SB,…”
Category
SA
SB
Related Ind
Definitions
Straight Min None
Engine Test Requirements
Inhibited only CRC L-4
Sequence IIA
Sequence IIIA
SC
1964 Models
CRC L-38
Sequence IV
Sequence IIA
Sequence V
Sequence IIIA
Fuel -1% S
SD
1968 Models
CRC L-38
Sequence IIB
Sequence IV
Sequence VB
Caterpillar L-1 Caterpillar IH
Sequence IIIB
Falcon Rust
SE
1972 Models
CRC-L-38
Sequence IIB
Sequence IIID Sequence VC
Sequence IIIC
Sequence VD
SF
1980 Models
CRC-L-38
Sequence IID
Sequence IIIE Sequence VD
Sequence IIID
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API Automotive Gasoline Engine
Service Categories – “SA, SB,…”
Category
SG
SH
Related Ind
Engine Test Requirements
Definitions
1989 Models CRC-L-38
Sequence IID
Sequence IIIE
Sequence VE Caterpillar IH2
1994 Models
CRC-L-38
Sequence VE
Sequence IID
Sequence IIIE
Category SA, SB, SC, SD, SE,SF,SG,SH have been declared as obsolete.
SJ
1997 Models
CRC-L-38
Sequence VE
Sequence IID
SL
2001 Models
Sequence IIIF Sequence IVA
Sequence VIII
Sequence VG
SM
2004 Models
Sequence IIIG Sequence IVA
Sequence VIII
Sequence VG
Sequence IIIE
Category SJ, SL, SM, are currently valid.
Hussam Adeni
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API Automotive Diesel Engine
Service Categories – “CA, CB,…”
Category
CA
CB
CC
CD
CD-II
Related
US Mil spec
MIL-L-2104A
Engine Test Requirements
CRC L-38
MIL-L-2104A
CRC
Supplement 1
MIL-L-2104B
CRC
MIL-L-46152B
MIL-L-2104C/D/E, CRC
MIL-L-45199B,
Series 3
MIL-L-2104D/E
CRC
2 stroke Hvy Dty
Caterpillar L-1
Fuel – 0.4% S
L-38
Caterpillar L-1
Fuel – 0.4% S
L-38
Sequence IID
Caterpillar IH2
L-38
Caterpillar I G2
L-38
Caterpillar 1 G2 Detroit Diesel
6V53T
Caterpillar 1 G2 Cummins NTC 400
Mack T-7
CE
None
CRC L-38
Mack T-6
CF
None
CRC L-38
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Caterpillar 1M-PC
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API Automotive Diesel Engine
Service Categories – “CA, CB,…”
Category
CF-2
CF-4
Related Ind
Engine Test Requirements
Spec
None
CRC L-38 Detroit Diesel 6V92TA Caterpillar 1M-PC
None
CRC L-38 Cummins NTC-400
Mack T-7
CRC L-38 Sequence IIIE
Mack T-8 RFWT
Mack T8E Sequence IIIE
RFWT
Mach T-9
Caterpillar 1K
Caterpillar 1R, 1K
Sequence IIIF
CG-4
None
CH-4
None
CI-4
None
RFWT
EOAT
Cummins M11 EGR
Mack T-8E, T-10
CI-4Plus
None
RFWT
EOAT
Cummins M11 EGR
Caterpillar 1R, 1K
Mack T-8E, T-10,T-11 Sequence IIIF
Caterpillar 1N
Caterpillar 1P, 1K
Cummins M 11
CA to CE obsolete; CF onwards are currently valid
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ISO 3448 – Kin Vis - CSt 40˚C
vs SUS 100˚F (40˚C)
Midpoint
Minimum
VG 2
VG 3
2.2
3.2
1.98
2.88
2.42
3.52
VG
VG
VG
VG
4.6
6.8
10
4.14
6.12
9
5.06
7.48
11
15
22
13.5
19.8
16.5
24.2
32
46
28.8
41.4
35.2
50.6
5
7
10
15
VG 22
VG 32
VG 46
Hussam Adeni
Maximum
SUS 100˚F
60
75
105
150
215
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ISO 3448 – Kin Vis - CSt 40˚C
versus SUS 100˚F (40˚C)
Midpoint
Minimum
VG 68
VG 100
68
100
61.2
90
74.8
110
315
465
VG
VG
VG
VG
150
220
320
135
198
288
165
242
352
460
680
414
612
506
748
700
1000
1500
2150
1000
1500
900
1350
1100
1650
150
220
320
460
VG 680
VG 1000
VG 1500
Hussam Adeni
Maximum
SUS 100˚F
3150
4650
7000
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National Lubricating Grease
Institute - NLGI Numbers
NLGI Grade Number
ASTM worked penetration 77˚F
(25˚C)
000
00
0
1
2
3
4
445
400
355
-
475
430
385
310
265
220
-
340
295
250
175
130
85
5
6
Hussam Adeni
- 205
- 160
- 115
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Thank you
Hussam Adeni
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