Optimization of Extreme Load and Break-in Period in Plain ZDDP Oil with FeF3 Catalyst Using Design of Experiment and Fundamental Study under Different Speeds

Abstract

The mechanism of tribofilm formation and breakdown was carefully followed and studied in 0.1 P% (percentage phosphorus content) plain zinc dialkyldithiophosphate (ZDDP) oil in the presence of iron fluoride (FeF3) catalyst under extreme Hertzian contact pressure (3.0 GPa) and two different rotational speeds or variable speed with break in period (100 rpm for the first 5,000 revolutions and a 700 rpm until failure or 100,000 revolutions, whichever comes first). At the onset of large frictional fluctuations, the contact surface temperature increased significantly and reached 90°C ± 5°C. The present article describes an innovative method of reducing the surface temperature by using a break in period of 2 or 3 min and rerunning the test until failure. The two different rotational speeds or variable speed will be compared to a steady-state speed of 700 rpm.Thermal decomposition of ZDDP is examined in the presence of powder and dispersed FeF3 using differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Surface analyses were carried out using scanning electron microscopy (SEM) coupled with X-ray of the wear tracks, transmission electron microscopy (TEM), and auger electron spectroscopy (AES). Results showed that submicrometer dispersed FeF3 provided excellent wear protection when combined with ZDDP in the variable-speed test with break-in by forming a tribofilm that is amorphous in nature and rich in phosphorus, which was shown by the TEM and X-ray analyses.