The Basics of Lubricants and lubrication Hussam Adeni Lube.specialist@gmail.com 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 Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com Methods of lubrication cont.. • Two main methods • Hydrodynamic lubrication • Boundary lubrication • Boundary lubrication • Occurs when Hydrodynamic lubrication fails. • By adsorption or chemical reaction Hussam Adeni Lube.specialist@gmail.com Types of Lubricant - Physical • Liquid • Solid • Semi solid • Gases Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com Typical lubricants - Application • Engine oils • Gear Oils • Turbine Oils • Hydraulic Oils • Metal working oils • Cutting oils • Forming Oils • Rust preventives Hussam Adeni Lube.specialist@gmail.com Typical lubricants - Application • Heat Transfer Oils • Heat Treatment Oils • Quenching Oils • Tempering Oils • Refrigeration Oils • Rubber Process Oils • Ink process Oils Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com Function of a lubricant • Lubricate - Reduce friction • Cooling - Heat transfer • Cleaning - Detergency • Noise pollution - dampening • Sealing – prevent leakage • Protection – prevent wear Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com 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. Hussam Adeni Lube.specialist@gmail.com Cleaning • Cleans carbon and varnish deposits • Flushes the entire system removing • • • • • Soot Deposits Acids Wear products Moisture • Removes external contaminants dust, moisture (external) Hussam Adeni Lube.specialist@gmail.com Noise reduction • Reduce noise • By preventing metal to metal contact • Dampens noise • As between camshaft and tappet Hussam Adeni Lube.specialist@gmail.com Sealing • Oil film • Between piston ring and liner • Helps in creating a gas tight seal Hussam Adeni Lube.specialist@gmail.com Protection • Protection against acids and moisture • Very important to increase life of component and equipment Hussam Adeni Lube.specialist@gmail.com Properties of lubricants • Kinematic viscosity • Viscosity index • Pour Point • Flash Point • Total Base Number (TBN) Hussam Adeni Lube.specialist@gmail.com Properties of lubricants • 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) Hussam Adeni Lube.specialist@gmail.com Kinematic Viscosity Recommendations • Low Viscosity oils used • High speeds • Low pressure • Low temperature • High Viscosity oils used • Low speeds • High pressure • High temperature Hussam Adeni Lube.specialist@gmail.com Properties of lubricants • 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 Hussam Adeni Lube.specialist@gmail.com Properties of lubricants • Pour Point • Lowest temperature at which the fluid will flow • Indicates lowest operating temperature • Measured in ˚C Hussam Adeni Lube.specialist@gmail.com Properties of lubricants • 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 Hussam Adeni Lube.specialist@gmail.com Properties of lubricants • 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 Hussam Adeni Lube.specialist@gmail.com Lab Tests - for lubricants Kinematic viscosity Viscosity index Pour Point Flash Point Total Base Number (TBN) Hussam Adeni ASTM ASTM ASTM ASTM ASTM ASTM D D D D D D 445 2250 97 92 (COC) 93 (PMCC) 664 Lube.specialist@gmail.com What are additives Lubricant additives classified on their functional capability Enhance existing property Suppress undesirable property Impart new property Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com Surface Protective additives Anti wear and EP Agent Corrosion & Rust inhibitor Detergent Dispersant Friction modifier Hussam Adeni Lube.specialist@gmail.com Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Anti wear & EP Agent Reduce friction & wear. Prevent scoring & seizure ZDDP, Organic Phosphates, acid phosphates, organic sulfur and chlorine compounds etc. Chemical reaction with metal surface and forms a film. Prevents metal-to-metal contact Hussam Adeni Lube.specialist@gmail.com Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Corrosion and Rust Inhibitor Prevent corrosion and rusting of the metallic parts in contact with lubricant ZDDP, Metal phenolates, Basic Metal sulphonates, fatty acid & Amines. Preferential adsorbtion of polar constituent on metal surface. Provide protective film Neutralize corrosive acids Hussam Adeni Lube.specialist@gmail.com Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Detergents Keep surface free of deposits Metallo organic compounds of Sodium, Calcium and Magnesium phenolates Phosphonates and sulphonates Chemical reaction with sludge and varnish percursors to neutralize them and keep them soluble Hussam Adeni Lube.specialist@gmail.com Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Dispersant Keep insoluble contaminants dispersed in the lubricant Alkylsuccinimides, alkylsuccinic esters and mannich reaction products Contaminants are bonded by polar attraction to dispersant molecules. Prevented from agglomerating Kept in suspension due to solubility of dispersant Hussam Adeni Lube.specialist@gmail.com Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Friction modifier Alters coefficient of friction Organic fatty acids and amides. Lard Oil, high molecular weight organic phosphorus. Phosphoric acid esters Preferential adsorbtion of surface active materials Hussam Adeni Lube.specialist@gmail.com Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Pour Point Depressant Enable lubricant to flow at lo temperature Alkylated naphthalene Phenolic polymers, Ploymethacrylates Maleate/fumerate copolymer esters Modify wax crystal formation to reduce interlocking Hussam Adeni Lube.specialist@gmail.com Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Seal swell Agent Swell elastomeric seals, gaskets Organic phosphates Aromatic hydro carbons Chemical reaction with with elastomer to cause slight swell. Hussam Adeni Lube.specialist@gmail.com Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Viscosity modifier Reduce the rate of viscosity change with temperature Polymers and copolymers of olefins, methacrylates, dienes Alkylated styrenes. Polymers expand with increasing temperatures This counteract oil thinning Hussam Adeni Lube.specialist@gmail.com Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Antifoamant Prevent lubricant from forming a persistent foam Silicone polymers Organic copolymers Reduce Surface tension to speed collapse of foam Hussam Adeni Lube.specialist@gmail.com Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Antioxidant Retard oxidative decomposition ZDDP, Hindered phenols, Aromatic Amines, sulfurized phenols Decompose peroxides Terminates free-radical reactions Hussam Adeni Lube.specialist@gmail.com Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Metal deactivator Reduce catalytic effect of metals on oxidation rate Organic complexes containing nitrogen or sulfur Amines, sulphides and Phosphates Forms inactive film on metal surfaces by complexing with metallic ions Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com 2000 1500 ISO VG AGMA 1500 1000 800 600 500 • Viscosity Grade Classification Systems 400 ISO – Industrial Oils • cSt @ 40°C AGMA – Industrial Gear Oils • cSt @ 40°C SAE – Engine Oils • • • cSt @100°C • cP @ -12°C to -55°C 8A 680 8 460 7 5000 3000 3000 2000 6 90 5 1000 40 100 3 30 1000 85W 80W 68 2 46 1 20 500500 400400 300 300 75W 200 200 32 22 10 140 4 30 20 15 5000 150 150 100 80 10000 50 220 200 SAE Gear Oils 2000 320 300 cSt @100°C, cP @150°C 60 50 cP @ -10°C to -40°C 40 SAE – Gear Oils 1000 SAE Engine Oils 15 10 cSt @ 40C SUS @ 100F 15W 10W 100 85W&0W 100 60 60 Lubricant - Specifications • Crankcase oils - SAE numbers • Crankcase oils - Performance levels • Crankcase oils – OEM Specifications • Viscosity classification • Grease specification Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com 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 Hussam Adeni Lube.specialist@gmail.com SAE Crankcase Oil - Viscosity classification – Winter Service SAE Viscosity Grade Low temp viscosities High temp viscosities Max. Temp for Vis. at 100˚C, Engine cranking High shear (cP) 150˚C Max. cPs at Temp pumping viscosity cSt of 60,000 cP(˚C) (˚C) Min Max & 106 S-¹ Min Winter Service 6200@ -35 0W 6200@ -30 5W 7000@ -25 10W 7000@ -20 15W 20W 25W 9500@ -15 13000@ -10 -40 -35 -30 -25 -20 -15 Hussam Adeni 3.8 3.8 4.1 5.6 5.6 9.3 - -- - - Lube.specialist@gmail.com SAE Crankcase Oil - Viscosity classification – Summer Service SAE Viscosity Grade Low temp viscosities High temp viscosities Max. Temp for Vis. at 100˚C, cSt Engine High shear pumping (cP) 150˚C & cranking Max. viscosity of Min Max 106 S-¹ Min cPs at Temp 60,000 cP(˚C) (˚C) Summer Service -20 -30 -40 -40 -50 -60 - 5.6 <9.3 2.6 - 9.3 12.5 <12.5 <16.3 2.9 3.5 - 12.5 <16.3 3.7 - 16.3 <21.9 3.7 - 21.9 <26.1 3.7 Hussam Adeni Lube.specialist@gmail.com API Automotive Gasoline Engine Service Categories – “SA, SB,…” Category SA SB Related Ind Definitions Straight Min None Engine Test Requirements Inhibited only CRC L-4 Sequence IIA Sequence IIIA SC 1964 Models CRC L-38 Sequence IV Sequence IIA Sequence V Sequence IIIA Fuel -1% S SD 1968 Models CRC L-38 Sequence IIB Sequence IV Sequence VB Caterpillar L-1 Caterpillar IH Sequence IIIB Falcon Rust SE 1972 Models CRC-L-38 Sequence IIB Sequence IIID Sequence VC Sequence IIIC Sequence VD SF 1980 Models CRC-L-38 Sequence IID Sequence IIIE Sequence VD Sequence IIID Hussam Adeni Lube.specialist@gmail.com API Automotive Gasoline Engine Service Categories – “SA, SB,…” Category SG SH Related Ind Engine Test Requirements Definitions 1989 Models CRC-L-38 Sequence IID Sequence IIIE Sequence VE Caterpillar IH2 1994 Models CRC-L-38 Sequence VE Sequence IID Sequence IIIE Category SA, SB, SC, SD, SE,SF,SG,SH have been declared as obsolete. SJ 1997 Models CRC-L-38 Sequence VE Sequence IID SL 2001 Models Sequence IIIF Sequence IVA Sequence VIII Sequence VG SM 2004 Models Sequence IIIG Sequence IVA Sequence VIII Sequence VG Sequence IIIE Category SJ, SL, SM, are currently valid. Hussam Adeni Lube.specialist@gmail.com API Automotive Diesel Engine Service Categories – “CA, CB,…” Category CA CB CC CD CD-II Related US Mil spec MIL-L-2104A Engine Test Requirements CRC L-38 MIL-L-2104A CRC Supplement 1 MIL-L-2104B CRC MIL-L-46152B MIL-L-2104C/D/E, CRC MIL-L-45199B, Series 3 MIL-L-2104D/E CRC 2 stroke Hvy Dty Caterpillar L-1 Fuel – 0.4% S L-38 Caterpillar L-1 Fuel – 0.4% S L-38 Sequence IID Caterpillar IH2 L-38 Caterpillar I G2 L-38 Caterpillar 1 G2 Detroit Diesel 6V53T Caterpillar 1 G2 Cummins NTC 400 Mack T-7 CE None CRC L-38 Mack T-6 CF None CRC L-38 Hussam Adeni Caterpillar 1M-PC Lube.specialist@gmail.com API Automotive Diesel Engine Service Categories – “CA, CB,…” Category CF-2 CF-4 Related Ind Engine Test Requirements Spec None CRC L-38 Detroit Diesel 6V92TA Caterpillar 1M-PC None CRC L-38 Cummins NTC-400 Mack T-7 CRC L-38 Sequence IIIE Mack T-8 RFWT Mack T8E Sequence IIIE RFWT Mach T-9 Caterpillar 1K Caterpillar 1R, 1K Sequence IIIF CG-4 None CH-4 None CI-4 None RFWT EOAT Cummins M11 EGR Mack T-8E, T-10 CI-4Plus None RFWT EOAT Cummins M11 EGR Caterpillar 1R, 1K Mack T-8E, T-10,T-11 Sequence IIIF Caterpillar 1N Caterpillar 1P, 1K Cummins M 11 CA to CE obsolete; CF onwards are currently valid Hussam Adeni Lube.specialist@gmail.com ISO 3448 – Kin Vis - CSt 40˚C vs SUS 100˚F (40˚C) Midpoint Minimum VG 2 VG 3 2.2 3.2 1.98 2.88 2.42 3.52 VG VG VG VG 4.6 6.8 10 4.14 6.12 9 5.06 7.48 11 15 22 13.5 19.8 16.5 24.2 32 46 28.8 41.4 35.2 50.6 5 7 10 15 VG 22 VG 32 VG 46 Hussam Adeni Maximum SUS 100˚F 60 75 105 150 215 Lube.specialist@gmail.com ISO 3448 – Kin Vis - CSt 40˚C versus SUS 100˚F (40˚C) Midpoint Minimum VG 68 VG 100 68 100 61.2 90 74.8 110 315 465 VG VG VG VG 150 220 320 135 198 288 165 242 352 460 680 414 612 506 748 700 1000 1500 2150 1000 1500 900 1350 1100 1650 150 220 320 460 VG 680 VG 1000 VG 1500 Hussam Adeni Maximum SUS 100˚F 3150 4650 7000 Lube.specialist@gmail.com National Lubricating Grease Institute - NLGI Numbers NLGI Grade Number ASTM worked penetration 77˚F (25˚C) 000 00 0 1 2 3 4 445 400 355 - 475 430 385 310 265 220 - 340 295 250 175 130 85 5 6 Hussam Adeni - 205 - 160 - 115 Lube.specialist@gmail.com Thank you Hussam Adeni Lube.specialist@gmail.com