A comprehensive review of water based lubrication technology

Although it is recognised that the move towards cleaner burning, higher efficiency engines requires operating temperatures in excess of 500°C, there are currently few practical means available to achieve this. Therefore, the development of cleaner, more efficient engines requires the use of new lubrication technologies. Any potential lubricant and lubrication technology must address the changing needs of the original equipment manufacturers (OEMs). Specifically, this should include material and fuel compatibility, increased lubrication performance at elevated temperatures and pressures, ashless deposits, reduced particulate emissions, and biodegradability. Over the past six years, various organisations have addressed many of these needs and have successfully demonstrated the use of phosphate esters as candidate vapour phase (VP) lubricants. With the correct choice of lubricant, VP lubrication has been effective in reducing friction and minimising wear of ferrous‐rich stainless and tool steels, alloys, ceramics and composites, at temperatures up to 670°C, under both sliding and rolling contact. This paper details the development of VP lubrication, and of sers some insights into materials and lubricant selection, and some examples of successful applications.

In 2016, the Vehicle Technologies Office (VTO) of the Department of Energy (DOE) issued a solicitation for the AOP Lab Call research in FY2017 on a number of topics related to vehicles. Topic 6A of the Lab Call focused on research related to advanced lubricants: '...(in) support of the lubricants program goal to, by 2020, demonstrate novel formulations for powertrain and driveline lubricants, compatible with new and legacy vehicles, to achieve at least a 4 percent real-world fuel economy improvement.' Argonne National Laboratory (ANL) in collaboration with Oak Ridge National Laboratory (ORNL) and Pacific Northwest National Laboratory (PNNL) was awarded a 3-year multilab project on 'Lubricant Technology - Innovation, Discovery, Design, and Engineering.' Research on the project began in FY2017 at the three laboratories with industry participation; however, in FY2018, the project was terminated due to budgetary constraints. The following is the final report for the project and highlights progress made during the first year of research. The report is divided into sections that highlight the following: goals, objectives, milestones and deliverables; project highlights; outreach - publications, conferences, and reports; milestones accomplished; research progress.

The application of new lubrication technology has a close relationship with the industrial development of automobile, machinery and transportation. Energy saving and environment protection are main two factors to push lubricants upgrades. Lubricant quality and correct application directly influence the use-life of machine, consumption of energy and environment protection. All over the world, especially in Western developed countries people pay more attention to the research and application of new lubricant technology. The lubricant specifications were reviewed and upgraded continuously according to the requirements of machine, fuel economy and emission. China’s sustained development means the ability to satisfy current human’s requirement as well as not to destroy nature resources for next generation. That also means we must balance the fast development of economy, society, resources and environment, we must protect natural resources and environment such as water, ocean, lands and forest which we live on, which can keep our next generation developing. Research and application of new lubricant technology is basic issues to keep China’s economy continuously growing. China’s petroleum consumption increased rapidly during the recent decades. There are two rapid period within 25 years after China’s application of opening and reform policy. The first is from 1978 to 1990, the whole petroleum consumption increased from 913 million to 1.18 billion tons respectively, increasing rate is 2.0% per year. The second was from 1991 to 2003, petroleum consumption increased from 1.18 billion to 2.74 billion tons, increasing rate was up to 6.7% per year. If we compare 2003 with 2001, the net petroleum consumption amount had increased 42million tons, increase rate is 8.7% per year. China now becomes one of biggest petroleum consumption country. The efficiency of China’s petroleum consumption is low. According to world petroleum consumption level (ton per thousand U.S. Dollar, GDP), China consumes four times more petroleum than that of Japan, three times of that of European, two times of that of USA. The wide application of low-grade lubricating oil and the lack of new lubrication technology are the main cause of the low-efficient petroleum usage. In the future decades petroleum shortages will be more and more strict in China, and it will have an important role in the delay of economic development and national safety. It is our lubricants workers duty to develop and apply the new lubrication technology to enhance the use efficiency of petroleum, to prevent our reliable environment and to push the China’s sustainable development. The world total consumption quantity of lubricating oil keeps about 37 to 39 million tons per year. It shares about 1% of total crude refining amount. The lube consumption amount in North American keeps stable about 9.5 million tons which listed No.1 while European and previous Unit Soviet area decreased. Asia is the only increased area, mainly because of the fast economic growth in China and India. China has consumed 4.4million tons lubricating oil in 2003, take about 1.6% of total crude refining amount, shares about 11% of whole world consumption amount, values about 22 billion RMB [1]. The increased rate reaches the highest—10.56% compared to 2002. This was the first time China become the second lubricant consumer in the world, just after USA. In 2004, China’s lubricants consumption will reach over 5 million tons, reaches the top in history, the increased rate will reach 10% comparing with 2003. China’s Automobile industry develops rapidly in the recent years, at the same time fuel efficiency keeps a low level. In 2002 China’s automobile has consumed 2.28 ton fuel per automobile which is 110–120 percent of USA, 200 percent of Japan. There exists a wide market for the application of new lubrication technology. The application of those additives and lube oils such as environment-friend additives, friction modified agents, nano-lube additives, energy-conserving multi-grade lube oils can enhance lubrication efficiency of equipments, decrease fuel consumption and conserve the petroleum resources. In this paper the applications of Cu nano-lube additive are introduced. and 0.1% Cu nano-lube is added into passenger car motor oil 5W30 SJ. The four-ball test equipment, cam-tappet test equipment and MS VI engine test are used to evaluate the performance, the test results shows the application of Cu nano-additive can obviously decrease the friction coefficient and fuel consumption. China should establish its national lube oil evaluation system, this system can greatly push the warranty of the quality of lube oil. The standard and national principle for fuel-conserving should be acted to improve the application of multi-grade lube oil and energy-conserving lube oil and new technology.

The article considers the problem of increased wear of the wheel-rail pair. An effective solution to this problem is the use of technical means of lubrication, which ensure a reduction in the wear rate of the crests of rolling stock wheels. Based on the survey of modern foreign and domestic lubrication devices and technologies, the main types of flange lubrication systems are identified: onboard (on rolling stock), track stationary, mobile rail-lubricators. The main shortcomings of the existing lubrication systems have been identified: the complexity of the construction of flange lubrication systems, the accuracy of lubricant application on the wheel flange, the lack of control over the serviceability of equipment (onboard and stationary combs), the lack of free paths in the graph for skipping mobile rail-lubricators, especially on single-track line considering the low speed of their operation. These drawbacks lead to the conclusion that at present there are no lubrication technologies that fully meet the conditions of the wheel-rail pair operation. A developed device is proposed that allows accurately applying a lubricant in the form of a solid lubricating element to the wheel flanges of the rolling stock and to provide an automated supply of lubricant in the temperature range of the operation of the rolling stock flanges. Authors described the mechanism of operation of the proposed device for lubricating the wheel flange, which ensures the flow of solid lubricant to the interacting surfaces.

In 2016, the Vehicle Technologies Office (VTO) of the Department of Energy (DOE) issued a solicitation for the AOP Lab Call research in FY2017 on a number of topics related to vehicles. Topic 6A of the Lab Call focused on research related to advanced lubricants: “…(in) support of the lubricants program goal to, by 2020, demonstrate novel formulations for powertrain and driveline lubricants, compatible with new and legacy vehicles, to achieve at least a 4 percent real-world fuel economy improvement.” Argonne National Laboratory (ANL) in collaboration with Oak Ridge National Laboratory (ORNL) and Pacific Northwest National Laboratory (PNNL) was awarded a 3-year multilab project on “Lubricant Technology - Innovation, Discovery, Design, and Engineering.” Research on the project began in FY2017 at the three laboratories with industry participation; however, in FY2018, the project was terminated due to budgetary constraints. The following is the final report for the project and highlights progress made during the first year of research. The report is divided into sections that highlight the following: Goals, objectives, milestones and deliverables, project highlights, outreach – publications, conferences, and reports, milestones accomplished, and research progress.

Advancement in lubricant technology is driven by technical demands, oil market, innovations from related chemical areas and other conventional factors. Nevertheless, a personal impact of an individual scientist can also be very important. Few individuals can claim to have accelerated lubricant progress more than Dr. Joseph M. Perez, who initiated many new developments in lubricant technology and drove them to large scale implementation. Early in his career at PennState he worked on aerospace lubricants, developing highly efficient additives for supersonic planes. When working at Caterpillar he dealt with hydraulic fluids, gear oils and many heavy duty lubricants. During employment at NIST and upon return to PennState Dr. Perez realized the importance of vegetable oils. He pioneered many research directions for their applications, becoming directly involved in vegetable-based engine oils, hydraulic fluids, greases, biodiesel, elevator fluids and many other areas. His innovative thinking, enthusiasm and initiatives will be sorely missed by lubricant researchers.

<div class="htmlview paragraph">Since the 1970's, governmental organisations in Europe, USA and Japan have started to set exhaust gas emission limits on new vehicles. The regulation of emissions has now spread to South America, Australia, India and much of the Far East. Governmental agencies are primarily concerned with environmental effects of engine emissions. Regulated emissions limit the amount of carbon monoxide, hydrocarbons, oxides of nitrogen and particulates in the exhaust stream. These limits have been regularly reduced and future reductions have already been set as far ahead as 2010.</div> <div class="htmlview paragraph">In order to meet these limits, engine manufacturers are continually redesigning their engines. For heavy duty diesel (HDD) applications this has primarily meant improvements in combustion through turbo charging, intercooling and higher fuel injection pressures and in some cases the use of exhaust gas recirculation (EGR). To meet the future emission level limits in Japan, Europe and the USA, OEMs have indicated their intention to use exhaust after treatment devices to further reduce pollutant levels.</div> <div class="htmlview paragraph">All these changes to engine technology have demanded changes in lubricant technology. This has generally meant significant formulation changes incorporating more highly refined basestocks and the use of novel additive technology.</div> <div class="htmlview paragraph">This paper outlines the major changes in HDD emission limits, the corresponding changes in engine technology to meet those limits and their effects on lubricant technology. It shows that lubricant development to meet these requirements is well underway, but there are still significant challenges and unknowns to be faced before such oils are fully developed.</div>

Annual progress report for Fuel & Lubricant Technologies. The Fuel & Lubricant Technologies Program supports fuels and lubricants research and development (R&D) to provide vehicle manufacturers and users with cost-competitive options that enable high fuel economy with low emissions, and contribute to petroleum displacement.

It is estimated by some that 6–7% of the US GDP each year is lost due to lubrication and wear related failure. While engineering and materials technology continues to evolve in a well-understood way, lubricant technology has itself evolved but in far less understood terms. Lubricant technology has been developed allowing for better performance in today's extremely demanding applications, and with proper understanding of key features and benefits of modern lubricants and how to apply them to best realize those benefits, it is possible to improve equipment reliability and maximize total cost of ownership of today's high performance specialty lubricants. With regard to high voltage switchgear and circuit breakers, advanced technology lubricants have been demonstrated to provide long service life and represent one possible method to increase reliable operation due to their enhanced ability to perform at temperature extremes, resist drying out and ability to help prevent wear and corrosion.

The influence of the amount and dispersion of technological lubricant (zinc stearate) and solid lubricants (talc, graphite, calcium fluoride) as well as the sintering temperature and time on the physical and mechanical properties of sintered iron is studied. When the stock contains no technological lubricant the porosity of the specimens drops to 5.0–5.2% but their strength is substantially greater than that of SP10 and SP30 steels of the same porosity. The strength of the specimens is highest when the iron powder has the smallest grain size. Solid lubricants in the stock result in the pressed iron-powder parts having poorer mechanical properties, although they do act in part as technological lubricants during compaction. Favorable results may be obtained by complex alloying of the stock, i.e., the simultaneous introduction of several solid lubricants.

On the basis of the previously obtained theoretical curve of the dependence of the friction coefficient on the sliding speed, in this work, it is compared with the experimental studies of A.P. Grudeva, V.K. Belosevich. As a result, we came to the conclusion that the basis for studying the friction mechanism during cold rolling with technological lubrication can be a contact hydrodynamic model of friction. This model considers the mechanism of lubrication action and friction under conditions of heavy loaded contact with thin film lubrication.The aim of this work is to study the friction coefficient during cold rolling of steel from the standpoint of the contact-hydrodynamic theory. In this work, a non-monotonic function is derived that describes the change in the friction coefficient in a heavily loaded contact and a program has been developed for the joint solution of this equation and a contact-hydrodynamic model of the lubricant layer thickness by the method of successive approximations in order to determine the friction coefficient. The results of calculating the friction coefficient and its comparison with experimental data during cold rolling with the use of technological lubrication according to the method proposed in the work showed that the calculations according to the proposed method give results somewhat lower than those of A.P. Grudev, but higher than the values obtained by V.K. Belosevich. Calculations of the friction coefficient using the formula of V.A. Nikolaev and according to the proposed method are quite close. This will make it possible to use the proposed technique when determining the coefficient of friction under conditions of contact-hydrodynamic friction.As a result, it can be noted that, based on the study of the thickness of the lubricant layer in the deformation zone and experimental data associated with friction at the contact of the metal with the rolls, as well as the analysis of the contact-hydrodynamic theory, a method was developed for determining the friction coefficient during cold rolling using technological lubricant.

Results of industrial research are presented aimed at increasing durability of press stamps during hot forging operations due to effective environmentally friendly water-based graphite technological lubricants and heat-resistant stamp steel grades developed by authors of this paper. In particular, the durability of press stamps with usage of widely used oil-graphite technological lubricants such as ‘industrial oil and 25% of silver graphite’ and ‘Ukrinol-7’ was investigated. In addition, results of studies of stamps durability when using water-graphite lubricant ‘B1’ during hot extrusion operations of steel forgings are presented. It has been established that lubricant ‘B1’ makes it possible to increase the durability of press stamps by 20% in comparison with factory oil-graphite lubricant and to obtain similar durability in comparison with lubricant ‘Ukrinol-7’. Results of testing heat-resistant stamp steel grades 4X4N12BFC (Di-22) and 30X6MAFL are presented. Comparison of stamps durability made of above given steel grades and steel grade 5XHM showed that usage of steel grade Di-22 makes it possible to increase durability of stamps by more than 2 times and usage of steel grade 30X6MAFL makes it possible to increase durability of stamps by more than 4 times.KeywordsLubricantStampDurabilityGraphiteSteelEfficiencyPressHeatingOilWearForging

Part I: Base Oils 1 Base oils from petroleum R.J. Prince 2 Synthetic base fluids M. Brown, J.D. Fotheringham, T.J. Hoyes, R.M. Mortier, S.T. Orszulik, S.J. Randles and P.M. Stroud Part II: Additives 3 Friction, wear and the role of additives in controlling them C.H. Bovington 4 Oxidative degradation and stabilisation of mineral oil based lubricants G. Aguilar, G. Mazzamaro and M. Rasberger 5 Viscosity index improvers and thickeners R.L. Stambaugh and B.G. Kinker 6 Miscellaneous additives and vegetable oils J. Crawford, A. Psaila and S.T. Orszulik 7 Detergents and Dispersants E.J. Seddon, C.L. Friend and J.P. Roski Part III: Applications 8 Industrial lubricants C. Kajdas, A. Karpinska, and A. Kulczycki 9 Formulation of Automotive Lubricants D. Atkinson, A.J. Brown and G. Lamb 10 Driveline Fundamentals and Lubrication I. Joseph 11Aviation Lubricants A.R. Lansdown and S. Lee 12 Liquid Lubricants for Spacecraft Applications S. Gill and A. Rowntree 13 Marine lubricants B.H. Carter and D. Green 14 Lubricating Grease G. Gow Part IV: Performance 15 Lubricants and their environmental impact C.I. Betton 16 Oil Analysis and Condition Monitoring A. Toms and L. Toms 17 Automotive Lubricant Specification and Testing M.F. Fox

Research on the chemistry and technology of lubricants is a basic research direction in the scientific school of Professor N. I. Chernozhukov, created more than 50 years ago. The results of this school’s research have significantly expanded the ideas concerning the production and use of oils and greases and the effect of the nature of the stock on the relationship of the composition (colloidal structure) and properties of the commercial products obtained.

Chemistry and Technology of Lubricants