the basics of lubricants and lubrication

The Basics of Lubricants and lubrication

Hussam Adeni

[email protected]

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

Hussam Adeni [email protected]

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


Methods of lubrication cont..

• Two main methods• Hydrodynamic lubrication• Boundary lubrication

• Boundary lubrication• Occurs when Hydrodynamic lubrication

fails.• By adsorption or chemical reaction


Types of Lubricant - Physical

• Liquid• Solid• Semi solid• Gases


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


Typical lubricants - Application

• Engine oils• Gear Oils• Turbine Oils• Hydraulic Oils• Metal working oils

• Cutting oils• Forming Oils

• Rust preventives


Typical lubricants - Application

• Heat Transfer Oils• Heat Treatment Oils

• Quenching Oils• Tempering Oils

• Refrigeration Oils• Rubber Process Oils• Ink process Oils


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


Function of a lubricant

• Lubricate - Reduce friction• Cooling - Heat transfer• Cleaning - Detergency• Noise pollution - dampening• Sealing – prevent leakage• Protection – prevent wear


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


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.


Cleaning

• Cleans carbon and varnish deposits• Flushes the entire system removing

• Soot• Deposits• Acids• Wear products• Moisture

• Removes external contaminants dust, moisture (external)


Noise reduction

• Reduce noise• By preventing metal to metal contact

• Dampens noise• As between camshaft and tappet


Sealing

• Oil film• Between piston ring and liner• Helps in creating a gas tight seal


Protection

• Protection against acids and moisture

• Very important to increase life of component and equipment


Properties of lubricants

• Kinematic viscosity• Viscosity index• Pour Point• Flash Point• Total Base Number (TBN)



• 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)


Kinematic Viscosity - Recommendations

• Low Viscosity oils used• High speeds• Low pressure• Low temperature

• High Viscosity oils used• Low speeds• High pressure• High temperature



• 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



• Pour Point• Lowest temperature at which the fluid

will flow• Indicates lowest operating

temperature• Measured in ˚C



• 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



• 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


Lab Tests - for lubricants

ASTM D 445ASTM D 2250ASTM D 97ASTM D 92 (COC)ASTM D 93 (PMCC)ASTM D 664


Kinematic viscosityViscosity indexPour PointFlash Point

Total Base Number (TBN)

What are additives

Lubricant additives classified on their functional capability

Enhance existing property Suppress undesirable property Impart new property


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


Surface Protective additives

Anti wear and EP Agent Corrosion & Rust inhibitor Detergent Dispersant Friction modifier


Surface Protective additives - Automotive Lubricants

Additive type Purpose

Typical compounds

Function

Anti wear & EP AgentReduce friction & wear.Prevent scoring & seizureZDDP, Organic Phosphates, acid

phosphates, organic sulfur and chlorine compounds etc.

Chemical reaction with metal surface and forms a film.

Prevents metal-to-metal contact




Typical compounds

Function

Corrosion and Rust InhibitorPrevent corrosion and rusting of the

metallic parts in contact with lubricantZDDP, Metal phenolates, Basic Metal

sulphonates, fatty acid & Amines.

Preferential adsorbtion of polar constituent on metal surface.

Provide protective filmNeutralize corrosive acids



Additive type Purpose Typical compounds

Function

DetergentsKeep surface free of depositsMetallo organic compounds of Sodium,

Calcium and Magnesium phenolatesPhosphonates and sulphonatesChemical reaction with sludge and

varnish percursors to neutralize them and keep them soluble




Typical compounds Function

DispersantKeep insoluble contaminants

dispersed in the lubricantAlkylsuccinimides, alkylsuccinic esters

and mannich reaction productsContaminants are bonded by polar

attraction to dispersant molecules.Prevented from agglomeratingKept in suspension due to solubility of

dispersant




Function

Friction modifierAlters coefficient of friction Organic fatty acids and amides.Lard Oil, high molecular weight

organic phosphorus.Phosphoric acid estersPreferential adsorbtion of surface

active materials


Performance additives - Automotive Lubricants


Typical compounds

Function

Pour Point DepressantEnable lubricant to flow at lo

temperatureAlkylated naphthalenePhenolic polymers, PloymethacrylatesMaleate/fumerate copolymer esters Modify wax crystal formation to reduce

interlocking



Additive type Purpose Typical compounds Function

Seal swell AgentSwell elastomeric seals, gasketsOrganic phosphatesAromatic hydro carbonsChemical reaction with with elastomer

to cause slight swell.




Typical compounds

Function

Viscosity modifierReduce the rate of viscosity change

with temperaturePolymers and copolymers of olefins,

methacrylates, dienesAlkylated styrenes.Polymers expand with increasing

temperatures This counteract oil thinning




Typical compounds Function

AntifoamantPrevent lubricant from forming a

persistent foamSilicone polymers Organic copolymersReduce Surface tension to speed

collapse of foam




Function

AntioxidantRetard oxidative decompositionZDDP, Hindered phenols, Aromatic Amines,

sulfurized phenols Decompose peroxidesTerminates free-radical reactions




Typical compounds

Function

Metal deactivatorReduce catalytic effect of metals on

oxidation rateOrganic complexes containing

nitrogen or sulfurAmines, sulphides and PhosphatesForms inactive film on metal surfaces

by complexing with metallic ions


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


• Viscosity Grade Classification Systems

ISO – Industrial Oils

• cSt @ 40°C

AGMA – Industrial Gear Oils

• cSt @ 40°C

SAE – Engine Oils

• cSt @100°C, cP @150°C

• cP @ -10°C to -40°C

SAE – Gear Oils

• cSt @100°C

• cP @ -12°C to -55°C

2000 1500 1000 800 600 500 400 300 200 150 100 80 60 50 40 30 20 15 10 cSt @ 40C SUS @ 100F

100

60

200

300

500

1000

2000

3000

5000

1500

1000

680

460

320

220

150

100

68

46

32

22

15

10

1

2

3

4

5

6

7

8

8A

50

40

30

20

15W

10W 8 5W&0W

140

90

85W

80W

75W

400

100

60

200

300

500

1000

2000

3000

10000

5000

400

ISO VG AGMA SAE SAE Engine Gear

Oils Oils

Lubricant - Specifications

• Crankcase oils - SAE numbers • Crankcase oils - Performance levels• Crankcase oils – OEM Specifications• Viscosity classification• Grease specification


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


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


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


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


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


SAE Crankcase Oil - Viscosity classification – Winter Service


Low temp viscosities High temp viscosities

SAE Viscosity Grade

Engine cranking Max. cPs at Temp

(˚C)

Max. Temp for pumping viscosity of 60,000 cP(˚C)

Vis. at 100˚C, cSt High shear (cP) 150˚C & 106 S-¹ Min

Min Max

Winter Service

0W 6200@ -35 -40 3.8 - --

5W 6200@ -30 -35 3.8 -

10W 7000@ -25 -30 4.1 -

15W 7000@ -20 -25 5.6 -

20W 9500@ -15 -20 5.6 -

25W 13000@ -10 -15 9.3

SAE Crankcase Oil - Viscosity classification – Summer Service


Low temp viscosities High temp viscosities

SAE Viscosity Grade

Engine cranking Max. cPs at Temp

(˚C)

Max. Temp for pumping

viscosity of 60,000 cP(˚C)

Vis. at 100˚C, cSt High shear (cP) 150˚C & 106 S-¹ MinMin Max

Summer Service

20 -- - 5.6 <9.3 2.6

30 -- - 9.3 <12.5 2.9

40 -- - 12.5 <16.3 3.5

40 -- - 12.5 <16.3 3.7

50 -- - 16.3 <21.9 3.7

60 -- - 21.9 <26.1 3.7

API Automotive Gasoline Engine Service Categories – “SA, SB,…”


Category Related IndDefinitions

Engine Test Requirements

SA Straight Min None

SB Inhibited only CRC L-4 Sequence IIA Sequence IIIA

SC 1964 Models CRC L-38 Sequence IV

Sequence IIASequence V

Sequence IIIAFuel -1% S

SD 1968 Models CRC L-38Sequence IVCaterpillar L-1

Sequence IIBSequence VBCaterpillar IH

Sequence IIIBFalcon Rust

SE 1972 Models CRC-L-38Sequence IIID

Sequence IIBSequence VC

Sequence IIICSequence VD

SF 1980 Models CRC-L-38Sequence IIIE

Sequence IIDSequence VD

Sequence IIID

API Automotive Gasoline Engine Service Categories – “SA, SB,…”


Category Related IndDefinitions


SG 1989 Models CRC-L-38Sequence VE

Sequence IIDCaterpillar IH2

Sequence IIIE

SH 1994 Models CRC-L-38Sequence VE

Sequence IID Sequence IIIE

Category SA, SB, SC, SD, SE,SF,SG,SH have been declared as obsolete.

SJ 1997 Models CRC-L-38Sequence VE

Sequence IID Sequence IIIE

SL 2001 Models Sequence IIIFSequence VIII

Sequence IVA Sequence VG

SM 2004 Models Sequence IIIGSequence VIII

Sequence IVA Sequence VG

Category SJ, SL, SM, are currently valid.

API Automotive Diesel Engine Service Categories – “CA, CB,…”


Category Related US Mil spec


CA MIL-L-2104A CRC L-38 Caterpillar L-1 Fuel – 0.4% S

CB MIL-L-2104ASupplement 1

CRC L-38 Caterpillar L-1 Fuel – 0.4% S

CC MIL-L-2104BMIL-L-46152B

CRC L-38 Sequence IID Caterpillar IH2

CD MIL-L-2104C/D/E,MIL-L-45199B, Series 3

CRC L-38 Caterpillar I G2

CD-II MIL-L-2104D/E2 stroke Hvy Dty

CRC L-38 Caterpillar 1 G2 Detroit Diesel 6V53T

CE None CRC L-38Mack T-6

Caterpillar 1 G2Mack T-7

Cummins NTC 400

CF None CRC L-38 Caterpillar 1M-PC

API Automotive Diesel Engine Service Categories – “CA, CB,…”


Category Related IndSpec


CF-2 None CRC L-38 Detroit Diesel 6V92TA Caterpillar 1M-PC

CF-4 None CRC L-38Mack T-7

Cummins NTC-400 Caterpillar 1K

CG-4 None CRC L-38Mack T-8

Sequence IIIERFWT

Caterpillar 1N

CH-4 None Mack T8ERFWT

Sequence IIIEMach T-9

Caterpillar 1P, 1KCummins M 11

CI-4 None RFWTEOAT

Cummins M11 EGRMack T-8E, T-10

Caterpillar 1R, 1KSequence IIIF

CI-4Plus None RFWTEOAT

Cummins M11 EGRMack T-8E, T-10,T-11

Caterpillar 1R, 1KSequence IIIF

CA to CE obsolete; CF onwards are currently valid

ISO 3448 – Kin Vis - CSt 40˚C vs SUS 100˚F (40˚C)


Midpoint Minimum Maximum SUS 100˚F

VG 2 2.2 1.98 2.42

VG 3 3.2 2.88 3.52

VG 5 4.6 4.14 5.06

VG 7 6.8 6.12 7.48

VG 10 10 9 11 60

VG 15 15 13.5 16.5 75

VG 22 22 19.8 24.2 105

VG 32 32 28.8 35.2 150

VG 46 46 41.4 50.6 215

ISO 3448 – Kin Vis - CSt 40˚C versus SUS 100˚F (40˚C)


Midpoint Minimum Maximum SUS 100˚F

VG 68 68 61.2 74.8 315

VG 100 100 90 110 465

VG 150 150 135 165 700

VG 220 220 198 242 1000

VG 320 320 288 352 1500

VG 460 460 414 506 2150

VG 680 680 612 748 3150

VG 1000 1000 900 1100 4650

VG 1500 1500 1350 1650 7000

National Lubricating Grease Institute - NLGI Numbers


NLGI Grade Number ASTM worked penetration 77˚F (25˚C)

000 445 - 47500 400 - 4300 355 - 3851 310 - 3402 265 - 2953 220 - 2504 175 - 2055 130 - 1606 85 - 115

Hussam Adeni

Thank you

[email protected]

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