ROCOL UKA Di i i f ITW LTDA Division of ITW LTD

Defence & Aerospace Lubricants

ITW Rocol Defence & Aerospace Products

• Manufacture in Leeds, England• 130 employees

• Manufacturing capability:• Aerosols• Fluids/oils• Greases• Paints• Anti-Slip

• 1878: Founded as Ragosine Oil Co Ltd• 1953: ROCOL name established• 1968: Joined Morgan Crucible Plc• 1999: Acquired by ITW Inc

Grease Manufacturing & Packing

Manufacturing & Packaging on siteApproximately 750 tonnes p aApproximately 750 tonnes p.a.Batch size range from 50 kg to 1800 kg

MOD G d L b i tMOD Greases and Lubricants• Specialised manufacturer (flexible)• Auto, Semi Auto and Hand Package• Packing for Defence customers• Container size colour and material specific• Labelling as Required, NATO Codes, Batch

information, Contract Details etc.

Rocol MOD Specialist Lubricants

Supply Core UK MOD Aerospace Greases

G-354 / G-1353 XG-287 Aerospec 200, General Purpose Airframe Complex Lithium LubricantNew AMS-SAE 3052 and Airbus AIM 09-06-002 approved

G-382 / G-421 XG-291 Aerospec 300 Long Life High Load GreaseG-382 / G-421 XG-291 Aerospec 300, Long Life, High Load GreaseG-1352 XG-294 Aerospec 400, Developed to replace XG-293 as wheel bearing lubricant

XG-293 (basically MIL-PRF-81322), Aeroshell 22, Mobil 28

(Aerospec 400 XG 294 meets SAE AMS 3058 wheel bearing grease spec(Aerospec 400, XG-294 meets SAE AMS 3058 wheel bearing grease spec

Other Main MOD Lubricants include:-

D f S 91 8 XG 2 3 Ai f d GP hiDef Stan 91-85 XG-273 Aircraft grade GP graphite greaseG-353 XG-276 Aircraft low temp Moly GreaseG-355 XG-285 High Load GreaseDef Stan 91-64 XG-305 High Load Moly Greaseg yG-460 XG-286 Sea Water Resistant GreaseG-394 XG-315 Low Temp Silicone GreaseO-157 & Def Stan91/103 OX24 & PX36 Weapons Lubricants

Aerospace Approved Lubricants

Rocol Lubricants Rocol Lubricants Airbus Specified Products Include

Aerospec 100 Semi Fluid Lubricant

Rolls Royce Specified Products Include

Sapphire Endure High Performance PFPE, Aerospec 100 Semi Fluid Lubricant

Aerospec 200 General Airframe

Aerospec 3052 General Airframe (AMS 3052)

Extreme Pressure GreaseMHT Grease High Temp Moly Grease,

Heavy loaded slow bearingsMTLM (ZX38) General Purpose Anti Seize

Aerospec 400 (XG-294) Wheel Bearing (AMS 3058)

Aerospec Protect Corrosion Protective Spray, (undercarriage)

MTLM (ZX38) General Purpose Anti SeizeSapphire Precision High Temp Non chlorinated

Performance PFPE Spray Lubricant

Spray, (undercarriage)Anti Seize 797 Nickel / Graphite anti SeizeAnti Seize Spray Anti Seize for SS and

Nimonic AlloysDry Moly Paste Moly Disulphide dryDry Moly Paste Moly Disulphide dry

lubricantOxylube Resin bonded Moly Dry

Lubricant

B fit f Lithi ClBenefits of Lithium vs Claybased lubricantsbased lubricants

Benefits of Lithium Complex vs Clay based lubricants

1 Cost Savings!

2 Performance Improvements• Reduced corrosion• Improved wear and EP ProtectionImproved wear and EP Protection• Provide wider range of operating temperatures• Extended life, lower oxidation

3 Increased Availability & CompatibilityAll major commercial aircraft manufacturers have already

transitioned to Lithium complex general airframe greasestransitioned to Lithium complex general airframe greases, based on SAE AMS 3052 specification starting mid 1990’s (BMS 3-33, AIM 09-06-002)

SAE Commercial Aerospace “Core” Lithium Grease Standards

General Airframe (-73 °C to +121°C)Now majority of GA grease sold, capable of 90% plus of all

applications, operators seeing noticeable benefits

Wheel Bearings (-54 °C to +177°C)New specification intended to replace MIL 81322 clay

greases, improve current “ad hoc” products pp p gin corrosion and wear

SAE AMS 3052Airbus AIM 09 06 002

g p pproviding single industry standard, compatibility

SAE AMS 3058Airbus AIM 09 06 003Airbus AIM 09-06-002

Boeing BMS 3-33Airbus AIM 09-06-003Boeing TBC

Products IncludeRocol Aerospec 3052

Products IncludeRocol Aerospec 400p p

C i f Cl dComparison of Clay and Lithium TechnologyLithium Technology

What Are Greases ?

5 to 15 %Thickener

2 t 10 %either

Metal SoapsComplex Metal Soaps

Gels- greases

2 to 10 %Additives

can includeGels greases

PolyureasPolymers / Plastics

Anti WearTackifiers

Corrosion InhibitorsEP (Extreme Pressure)Additive

Thickener ( )Oxidation Inhibitors70% to 80 %

Oileither Oil

Thickener

either

Mineral OilSynthetic Oil

Semi-Synthetic Oil

Oil

Base Oils (70- 80% of the grease)

Mineral Oil Synthetic / Semi Synthetic• Cost Effective More Expensive (Life 5 to 10 times that of mineral)• Basic Oil (Distilled from Crude) Chemically Manufactured & Blended• Basic Oil, (Distilled from Crude) Chemically Manufactured & Blended• Limited Operating Temperature Wider Operating Temperatures (-90ºC to 300ºC)

Typical (-20ºC to 150ºC) Enhanced Performance (Typ. Wear)

PAO, Polyalphaolefin• Wide Temp Range (-55ºC to 200ºC)

Ester (di-ester)• Extreme Low and High Temps Possible

Other Advantages Include• Higher Film Strength Extreme Low and High Temps Possible

(-75ºC to 200ºC)

Perfluorinated (PFPE)• Oxygen Stability, Long Life, Good load carrying

I t & N ti R di ti St bl

• Higher Film Strength• Stronger Chemical Bond in Polymer Chain

Improved High TemperatureImproved Wear PropertiesHeavier Loads • Inert & Non-reactive, Radiation Stable

• Temp Range (-90ºC to 280ºC)Silicone Oil

• Long Light Duty Service Life• Wide Temp Range (-90ºC to 200ºC)

Heavier Loads• Improved Compatibility with Additives

Additives (2 to 10% of Grease)

Corrosion Inhibitors (sacrificial protective)

• Sulphonates (Barium / Calcium)Anti Wear Additives

• Phosphates & Dithio-Phosphates (engine oils)• Esters• PTFE

EP Extreme Pressure Additives• Chemicals Sulphur Compounds (react with surface Iron Sulphide)• Boron compounds• Solids (Molybdenum Disulphide, up to 100,000 psi 450ºC)

(Graphite , 15,000 to 20,000 psi up to 550ºC)Oxidation Inhibitors

• Amines or Phenol Compounds

Thickener Systems (10-15% of Grease)

Gel or CLAY “Soap”, “Metal Soaps or “Lithium” Greases

Traditionally Used In Many Greases

“Synthetic” Thickening Products – Excellent Scope for Additives

BENTONITE CLAY LITHIUM COMPLEX LITHIUM

(Latest Technology)

•None Melting •High temperature capabilities•Good Stability with Water

•Temperature range (typically -20ºC to + 150ºC)

•Moderate Water ResistanceG d C tibilit ith Additi

• Improved Temperature Range

(Drop Point typically >260ºC)• Good compatibility with additives

•Versatile & Low Cost

Disadvantage•Limited scope for Additives !

•Good Compatibility with Additive • Improved water washout• Improved shear stability• Longer service life

•Limited scope for Additives !

Benefits of Clay vs Lithium - Summary

Synthetic Lithium “Soap” Thickened greases have many potential advantages over Clay’s• Improved wear and EP / high load protection (especially high speed and temps)

• Much wider range of operating temperatures• Much wider range of operating temperatures

• Significantly better corrosion protection

• Controlled oil bleed, higher shear stability,

• Lower oxidation

• Improved Service Life!

This is generally as a result of the wider range of additives able to be used….

However….

Mixing different types of grease does not necessarily make a better Grease…

Co ld be a problem ith additi es (eg cla and lithi m de gelling)• Could be a problem with additives (eg clay and lithium – de-gelling)

• Reaction between additives (eg lithium / lithium - corrosion)

SAE AMS 3058 Wh l B i GSAE AMS 3058 Wheel Bearing GreaseSpecification History & CompatibilitySpecification History & Compatibility

SAE AMS 3058 Lithium Wheel Bearing Grease

Introduced - September 2008 • 3 yr development through SAE E34 Working group involving Airbus, Boeing, Shell, Mobil, Nyco,

Rocol, USMC and others

• SAE specification AMS 3058 intended as “core” similar to AMS 3052• SAE specification AMS 3058 intended as core similar to AMS 3052

• Airbus issues AIM 09-06-003 in February 09

• Boeing - TBC

AMS 3058 Specification Drivers• Enhance corrosion protection• Improved stability in presence of water• Low water washout• Reducing wear and improved EP performance• Align specification with AMS3052, General Airframe Specification

SAE AMS 3058 intended as replace• MIL-PRF-81322 clay grease (currently used in wheel bearings)

Oth lithi tl d b t t ti MIL Ai b SAE d ibl BMS• Other lithium greases currently used but not meeting MIL, Airbus, SAE and possible BMS spec

SAE AMS 3058 Lithium Wheel Bearing Greaseg

R l A 400 AMS 3058Rocol Aerospec 400 AMS 3058 Grease CompatibilityGrease Compatibility

Grease Compatibility Testing – Test What and Why ?

No Universal Standard for Testing• SAE Commercial Specification for Airframe Grease attempts to quantify

SAE AMS 3052 id h t CORE ti f G• SAE AMS 3052 considers changes to CORE properties of Grease mixtures ranging 10/90 to 90/10

What WhyDropping Point At what temperature will the grease mixture thin

and start to drip

Copper Corrosion Will the various additives in the grease start to react together and start to cause corrosion ?(Some EP additives can corrode steel if too much)

Oil Separation Will the grease mixture start to De-Gel ?

E t d d W k P t ti ( ft i f th G ) Will the structure of the grease start to break downExtended Work Penetration (softening of the Grease) Will the structure of the grease start to break down when the Lubricant is mechanically worked.

Any potential compatibility issues should start to effect these core properties first!

Drop Point and Copper Corrosion

• Drop point IP 396

• Copper Corrosion IP 112• 24 hours at 100 C24 hours at 100 C

Oil Separation

• Def Stan 05-50 Part 9• 30 hours at 177 C30 hours at 177 C

Shear StabilityExtended Worked Penetration

• Def Stan 05-50 Part 63100 000 t k

Extended Worked Penetration

• 100,000 strokes• With and without 10% water

Penetration

Shear Stability - Roll Stability

• ASTM D 18312 Hrs• 2 Hrs

• With and without 10% waterPenetration

Grease Compatibility Additional Testing

AMS 3058

EP Weld Load EMCOR Corrosion

AMS 3058• Test Method IP 220• 3% NaCl solution• SKF 1306K bearing

Beware (If no corrosion on outside ) Water soluble corrosion i hibit h b d !!!inhibitor has been used !!!

35

02

MIL 81322 AMS 3058

Weld Load N/S(Typ 230kg)

315kg min(Typ 355kg)

MHL 30min 50min

S Di IP239Scar Dia IP239, 1hr @40kg 70C 0.8max 0.7max

Why Use EMCOR “dynamic” Corrosion Tests?

TEST METHOD NUMBER TEST CONDITIONS ACCEPTANCE CRITERIA

1. Dynamic Rust Prevention Properties

IP220SKF Emcor

3% NaCl solution 0 rating

2 Salt Fog Test ASTM B117 38°C 5% NaCl Comparison

Example uses data for MIL PRF 23827 Type II clay (G-350) vs Lithium G-354

TEST METHOD NUMBER

MIX RATIOAEROSHELL 7 : AEROSPEC® 200

100:0 50:50 0:100

1 Dynamic Rust Prevention IP220 5 2 0

2. Salt Fog Test ASTM B117 38 C, 5% NaClsolution

Comparison

SH 33 AS200 SH 33/SH7 AS200/SH7 SH7 50/50 mix 50/50 mix

1. Dynamic Rust Prevention Properties

IP220SKF Emcor

5 2 0

2. Salt Fog Test ASTM B117

168h Clear Clear Clear

336h Clear Clear Clear

C C C

TEST METHOD NUMBER

MIX RATIOAEROSHELL 7 : AEROSHELL 33

100:0 50:50 0:1001. Dynamic Rust IP220 5 1 - 2 0

504h Clear Clear Clear

1. Dynamic Rust Prevention Properties

IP220SKF Emcor

5 1 2 0

2. Salt Fog Test ASTM B117168h Clear Clear Clear336h Clear Clear Clear504h Clear Clear Clear504h Clear Clear Clear

Grease Compatibility Conclusions

Replacing Clay NATO G-395 / MIL PRF 81322 with Lithium NATO G-1352

• G-1352 (Aerospec 400) Lithium Grease demonstrates good compatibility when mixed with 2 most widely used NATO G-395 / MIL PRF 81322 clay based greases

• Shear stability, oil separation and corrosion remain largely unaffected even with 50/50 mix

• 4 Ball EP, MHL and Wear data indicate that some performance criteria of NATO G395 clay grease may be exceeded by mixtures of clay and lithium (although not recommended)

Conclusions

• Airbus and Boeing will increasingly aim to standardise around 2 core lithium grease specifications, AMS 3052 and AMS 3058g p ,

• AMS 3058 has been specifically developed within the commercial aircraft industry to meet current and future requirements for aircraft wheel bearings

• AMS 3052 and 3058 lubricants have a high degree of commonality and compatibility

• Rocol Aerospec 400 has demonstrated good compatibility with both existing clay and lithium wheel bearing lubricants already in service

AMS 3058 lubricants have the potential to further

enhance performance and reduce costs

ROCOL UKTHANK YOUTHANK YOU