Transcript Folie 1 - LATEST RELEASES

High-Tech Lubricants for a World in Transition
 Engine Oils:
> Zinc-Free Low SAPS Engine Oil Technology
 Industrial Lubricants:
> New Phenomena in Hydraulic Systems
 Metalworking:
> Replacement of Chlorinated Paraffins in Fine Blanking Operations
> Cold Extrusion without applying Conversion Layers (Bondering)
 Steel Cold Rolling:
> Synthetic Cold Rolling Emulsions
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Zn-Free Low SAPS Engine Oils:
Formulation Technology
Zn-free – Why?
 Generally reduced ash formation -> better engine and AT devices
cleanliness, higher efficiency for aged engines
 Or: at equal ash formation -> more options for more important
performance improvements: e. g. cleanliness, better wear
protection, higher oxidation stability
 Impact on morphology of ash (hard/soft): e. g. injection nozzles
 Higher oxidation stability
 Better anti-wear protection
 Improvement of fuel economy
 Minimizing chemical interactions with AT devices: e. g. DeNOx
(Oxi-Cat, SCR)
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Zn-Free Low SAPS Engine Oils:
Impact on Morphology of Ash
Sulfated/oxide ashes
Ca-Sulfated/Oxide
ashes are like
“gypsum”
Sulfated/oxide ashes
Ca/Zn-Sulfated/Oxide
ashes are like “ore”
hard
soft
Lead to more wear
Lead to less wear
Ca-sulfated/oxide are
softer and are removed
“easier” during normal
operation from injector
nozzle, piston crown as
well as from cylinder head
than Zn-sulfate/oxide!
Source: Gas engine oil field test with Ganymet Plus
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Zn-Free Low SAPS Engine Oils:
Viscosity Development at 100°C
GFC-Test: 170°C Oil Temp. + 10 L/h Synthetic air
55
Viscosity depending on time
50
45
40
V100 [cSt]
35
30
25
20
15
10
5
0
0
50
100
Time [h]
150
200
SHPDEO
UHPDEO
BIO-SHPDEO
TITAN CARGO MAXX 5W-30
ACEA C3 5W-30
FES 106-1601
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
250
Zn-Free Low SAPS Engine Oils:
TAN Development
GFC-Test: 170°C Oil Temp. + 10 L/h Synthetic air
12
TAN[ mg KOH/g]
10
8
6
4
2
0
0
50
100
Time [h]
150
200
SHPDEO 15W-40
UHPDEO 10W-40
BIO-SHPDEO 5W-40
FES 106-1601
TITAN CARGO MAXX 5W-30
ACEA C3 5W-30
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
250
Zn-Free Low SAPS Engine Oils:
Wear Control Optimization in RNT
VW-TDI 85kW Pump-injector (PD)
The activated tappet (56Co, 57Co)
Online measurement
Procedure (140 h): Breaking-in, Speed sequence, Polycyclic endurance run, Speed
sequence
Ash free (0 Zn) anti-wear protection
works very effectively against high
pressure wear during mixed friction
Accumulated tappet wear [nm]
5000
4500
5W-30/1 Test 1 (low Zn)
4000
5W-30/1 Test 2 (low Zn)
3500
3000
2500
2000
5W-30/2 (low Zn)
1500
GT1 0W-20 high SAPS (0 Zn)
1000
5W-30/4 (0 Zn)
GT1 0W-20 low SAPS (0 Zn)
500
0
0
20
40
60
80
100
Time [h]
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
120
140
160
180
200
Zn-Free Low SAPS Engine Oils:
Diesel Fuel Consumption Optimization
Fuel consumption in M111FE Test
(Reference RL 191 SAE 15W-40)
Candidates
Vis. grade
SAE
HTHS
mPas
Saving
%
Pkw HM A
Pkw HM B
Pkw HM C
10W-40
5W-30
0W-30
4,2
3,5
2,9
1,15
1,7
2,7
Containing Zinc
Containing Zinc
Containing Zinc
LS 3 Pkw
LS 6 Pkw
LS 7 Pkw
5W-30
5W-30
0W-30
3,5
3,05
3,05
2,14
2,62
3,09
Zinc-free
Zinc-free
Zinc-free
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Hydraulic Fluids:
Filtration of Zn and Ash Free Hydraulic Fluids
8
Multi-Pass Filterability Test Results
for Different Zn Free Hydraulic
Fluids:
pressure differential [bar]
7
6
5
1 % water (8.7 l/min, 65°C, 100
bar, 15 l volume, 3µm/6µm)
4
3
All Products fulfill DIN 51524-3 for
HLP Hydraulic Fluids
2
1
0
00
288
576
864
time [min]
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
1152
1440
Hydraulic Fluids:
Electrostatic Charges
- Zn containing
- Zn free, high treat
- Zn free, low treat
-R+O
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Hydraulic Fluids:
Micro Scratching
Zn free - high performance
Zn free – low performance
Pistons without Micro Scratches
Pistons with Micro Scratches
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Synthetic Cold Rolling Emulsions:
Control of Particle Size
Particle Size important to achieve high strength in the oil film.
O/W emulsion
W/O emulsion
Median:
6.03µm
Mean(vm):
6.83µm
Median:
5.02µm
Mean(vm):
5.13µm
Mode:
6.70µm
S.D.(vm):
3.46µm
Mode:
5.25µm
S.D.(vm):
1.73µm
Concent.:1.3E-004cc/ml
Conf(vm):
95.27%
15
Percentage dV/dD
20
6
Pe
rc16
en
ta
ge12
dV
/d
D
8
3
4
12
9
0
0.1
0
1.0
10.0
Size
100.0
in
1000.0
0.1
1.0
Microns
Particle Size important to keep oil consumption under control
CAJA5.505
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
10.0
Size in Microns
100.0
1000.0
Synthetic Cold Rolling Emulsions:
Plate Out and Sheet Cleanliness
Plate Out Evolution
800
700
4-Stand CRM
mg/m2
600
5-Stand CRM
500
400
Sheet Cleanliness
Evolution
300
200
100
0
Old
100
New
4-Stand
CRM
96
5-Stand
CRM
92
88
84
Old 1
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Old 2
New
Synthetic Cold Rolling Emulsions:
BAO Steel - Lubricity performance
Rolling Mill Productivity (ton/h)
Average Rolling Forces
8% higher production
340
1050
1025
320
Forces 8 %
lower
310
ton
ton/h
330
1000
975
300
950
290
New Oil
Reference Prod.
925
New Oil
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Reference Prod.
Synthetic Cold Rolling Emulsions:
Sidmar - Cleanliness out of BAF
% Cleanliness
Sidmar BAF Scotch Tape
88,0
87,5
87,0
86,5
86,0
85,5
85,0
84,5
84,0
83,5
83,0
82,5
HNX Scotch
H2 Scotch
2003
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
2004-2005 (w3)
2005 (w3-15)
Synthetic Cold Rolling Emulsions:
Sidmar - Lubricity performance
Ratio vs. 2004
(100)
Sidmar TDM 2. Avg. Rolling Forces
110
105
100
95
90
85
80
- 3.5 % lower
Energy
Consumption
Stand 1 Stand 2 Stand 3 Stand 4 Stand 5
12-13 % lower
Rolling Forces in
Stands 2 and 3
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
radial force / normal force
Chlorine-Free Fine Blanking:
Pin-on-Disc: Chlorinated Oil
test time / s
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
radial force / normal force
Chlorine-Free Fine Blanking:
Pin-on-Disc: Phosphorus-Sulfurous based Oil
test time / s
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
radial force / normal force
Chlorine-Free Fine Blanking:
Pin-on-Disc: New Technology
test time / s
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Chlorine-Free Fine Blanking:
Comparison of Friction Traces
Chlorin. oil
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
PEP/S oil
New oil
press capacity / kN
Bonder-Free Cold Extrusion:
Cup Drawing: Various Formulations
bonderized
Oil 3.1
Oil 3.2
Oil 3.3
hydraulic oil
punch way / mm
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
Bonder-Free Cold Extrusion:
No Bondering of Workpiece, New Lubricant and Tool Coating
raw
material
Lubricants Russia 2007
Moscow, November 28, 2007
Dr. Georg Lingg
formed with MoS2
(after cleaning)
formed with oil 3.2 or 3..1
(without cleaning)