Rocol Defence and Aerospace Lubricants

1. ROCOL UK
A Division of ITW LTD
Di i i f
Defence & Aerospace Lubricants

2. 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

3. Grease Manufacturing & Packing
Manufacturing & Packaging on site
Approximately 750 tonnes p a
p.a.
Batch size range from 50 kg to 1800 kg
MOD G
Greases and Lubricants
dL b i t
• 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.

4. Rocol MOD Specialist Lubricants
Supply Core UK MOD Aerospace Greases
G-354 / G-1353 XG-287 Aerospec 200, General Purpose Airframe Complex Lithium Lubricant
New AMS-SAE 3052 and Airbus AIM 09-06-002 approved
G-382 / G-421 XG-291 Aerospec 300 Long Life High Load Grease
300, Life,
G-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
400, XG-294
Other Main MOD Lubricants include:-
Def Stan 91 8
D fS 91-85 XG-273
XG 2 3 Aircraft grade GP graphite grease
Ai f d hi
G-353 XG-276 Aircraft low temp Moly Grease
G-355 XG-285 High Load Grease
Def Stan 91-64 XG-305 High Load Moly Grease
g y
G-460 XG-286 Sea Water Resistant Grease
G-394 XG-315 Low Temp Silicone Grease
O-157 & Def Stan91/103 OX24 & PX36 Weapons Lubricants

5. Aerospace Approved Lubricants
Rocol Lubricants Rocol Lubricants
Airbus Specified Products Include Rolls Royce Specified Products Include
Sapphire Endure High Performance PFPE,
Aerospec 100 Semi Fluid Lubricant
Extreme Pressure Grease
Aerospec 200 General Airframe MHT Grease High Temp Moly Grease,
Heavy loaded slow bearings
Aerospec 3052 General Airframe (AMS 3052)
MTLM (ZX38) General Purpose Anti Seize
Aerospec 400 (XG-294) Wheel Bearing (AMS 3058) Sapphire Precision High Temp Non chlorinated
Performance PFPE Spray
Aerospec Protect Corrosion Protective
Lubricant
Spray, (undercarriage)
Anti Seize 797 Nickel / Graphite anti Seize
Anti Seize Spray Anti Seize for SS and
Nimonic Alloys
Dry Moly Paste Moly Disulphide dry
lubricant
Oxylube Resin bonded Moly Dry
Lubricant

6. Benefits of Lithium vs Cl
B fit f Lithi Clay
based lubricants

7. Benefits of Lithium Complex vs Clay based lubricants
1 Cost Savings!
2 Performance Improvements
• Reduced corrosion
• Improved wear and EP Protection
• Provide wider range of operating temperatures
• Extended life, lower oxidation
3 Increased Availability & Compatibility
All major commercial aircraft manufacturers have already
transitioned to Lithium complex general airframe greases
greases,
based on SAE AMS 3052 specification starting mid 1990’s
(BMS 3-33, AIM 09-06-002)

8. SAE Commercial Aerospace “Core” Lithium Grease Standards
General Airframe (-73 °C to +121°C) Wheel Bearings (-54 °C to +177°C)
Now majority of GA grease sold, capable of 90% plus of all New specification intended to replace MIL 81322 clay
applications, operators seeing noticeable benefits
pp p g g
greases, improve current “ad hoc” products
p p
in corrosion and wear providing single industry standard, compatibility
SAE AMS 3052 SAE AMS 3058
Airbus AIM 09-06-002
09 06 002 Airbus AIM 09-06-003
09 06 003
Boeing BMS 3-33 Boeing TBC
Products Include Products Include
Rocol Aerospec 3052
p Rocol Aerospec 400
p

9. Comparison of Clay and
C i f Cl d
Lithium Technology

10. What Are Greases ?
5 to 15 %
Thickener
either 2 t 10 %
to
Metal Soaps
Additives
Complex Metal Soaps can include
Gels
Gels- greases
Polyureas Anti Wear
Polymers / Plastics Tackifiers
Corrosion Inhibitors
Additive
Thickener EP (Extreme Pressure)
( )
70% to 80 % Oxidation Inhibitors
Oil
either Oil
Mineral Oil
Synthetic Oil
Semi-Synthetic Oil

11. 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)
Oil, 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)
Other Advantages Include Ester (di-ester)
• Higher Film Strength • Extreme Low and High Temps Possible
• Stronger Chemical Bond in Polymer Chain (-75ºC to 200ºC)
Improved High Temperature
Perfluorinated (PFPE)
Improved Wear Properties • Oxygen Stability, Long Life, Good load carrying
Heavier Loads • I t & Non-reactive, Radiation Stable
Inert N ti R di ti St bl
• Improved Compatibility with Additives • Temp Range (-90ºC to 280ºC)
Silicone Oil
• Long Light Duty Service Life
• Wide Temp Range (-90ºC to 200ºC)

12. 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

13. Thickener Systems (10-15% of Grease)
Gel or CLAY “Soap”, “Metal Soaps or “Lithium” Greases
Traditionally Used In Many “Synthetic” Thickening Products – Excellent Scope for Additives
Greases
BENTONITE CLAY LITHIUM COMPLEX LITHIUM
(Latest Technology)
•None Melting •Temperature range • Improved Temperature Range
•High temperature capabilities (typically -20ºC to + 150ºC) (Drop Point typically >260ºC)
•Good Stability with Water •Moderate Water Resistance
• Good compatibility with additives
•Versatile & Low Cost •Good Compatibility with Additi
G dC tibilit ith Additive
• Improved water washout
• Improved shear stability
Disadvantage • Longer service life
•Limited scope for Additives !

14. 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
• 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…
• Could
Co ld be a problem with additi es (eg cla and lithi m – de gelling)
ith additives clay lithium de-gelling)
• Reaction between additives (eg lithium / lithium - corrosion)

15. SAE AMS 3058 Wh l B
Wheel Bearing G
i Grease
Specification History & Compatibility

16. 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
core
• 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)
• Other lithium greases currently used b t not meeting MIL Ai b
Oth lithi tl d but t ti MIL, Airbus, SAE and possible BMS spec
d ibl

17. SAE AMS 3058 Lithium Wheel Bearing Grease
g

18. Rocol A
R l Aerospec 400 AMS 3058
Grease Compatibility

19. Grease Compatibility Testing – Test What and Why ?
No Universal Standard for Testing
• SAE Commercial Specification for Airframe Grease attempts to quantify
• SAE AMS 3052 considers changes t CORE properties of G
id h to ti f Grease
mixtures ranging 10/90 to 90/10
What Why
Dropping 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 ?
Extended Work Penetration (softening of the Grease)
E t d dW kP t ti ( ft i f th G ) 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!

20. Drop Point and Copper Corrosion
• Drop point IP 396
• Copper Corrosion IP 112
• 24 hours at 100 C

21. Oil Separation
• Def Stan 05-50 Part 9
• 30 hours at 177 C

22. Shear Stability
Extended Worked Penetration
• Def Stan 05-50 Part 63
• 100 000 strokes
100,000 t k
• With and without 10% water
Penetration

23. Shear Stability - Roll Stability
• ASTM D 1831
• 2 Hrs
• With and without 10% water
Penetration

24. Grease Compatibility Additional Testing
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
inhibitor h b
i hibit has been used !!!
d
5 3
MIL 81322 AMS 3058
Weld Load N/S 315kg min
(Typ 230kg) (Typ 355kg) 2 0
MHL 30min 50min
Scar Di IP239
S Dia IP239,
1hr @40kg 70C 0.8max 0.7max

25. Why Use EMCOR “dynamic” Corrosion Tests?
Example uses data for MIL PRF 23827 Type II clay (G-350) vs Lithium G-354
TEST METHOD NUMBER TEST CONDITIONS ACCEPTANCE
CRITERIA
1. Dynamic Rust Prevention IP220 3% NaCl solution 0 rating
Properties SKF Emcor
Salt Fog Test ASTM B117 38 C,
38°C 5% NaCl Comparison
2.
2 solution
TEST METHOD MIX RATIO
NUMBER AEROSHELL 7 : AEROSPEC® 200
100:0 50:50 0:100
1.
1 Dynamic Rust Prevention IP220 5 2 0
Properties SKF Emcor
SH 33 AS200 SH 33/SH7 AS200/SH7 SH7
50/50 mix 50/50 mix 2. Salt Fog Test ASTM B117
168h Clear Clear Clear
336h Clear Clear Clear
504h Clear
C Clear
C Clear
C
TEST METHOD MIX RATIO
NUMBER AEROSHELL 7 : AEROSHELL 33
100:0 50:50 0:100
1. Dynamic Rust IP220 5 1-2 0
Prevention Properties SKF Emcor
2. Salt Fog Test ASTM B117
168h Clear Clear Clear
336h Clear Clear Clear
504h Clear Clear Clear

26. 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)

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

28. ROCOL UK
THANK YOU