basic-of-lubricants-lubrication.ppt

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
• Also called complete or full flow
• Occurs when two surfaces are
completed separated by a fluid film

Methods of lubrication cont..
• Two main methods
• 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 445
ASTM D 2250
ASTM D 97
ASTM D 92 (COC)
ASTM D 93 (PMCC)
ASTM D 664
Kinematic viscosity
Viscosity index
Pour Point
Flash 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

- 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

 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

 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

 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

 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

Performance additives
 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

 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.

 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

 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

 Additive type
 Purpose
 Typical
compounds
 Function
Antioxidant
Retard oxidative decomposition
ZDDP,
Hindered phenols, Aromatic Amines,
sulfurized phenols
Decompose peroxides
Terminates free-radical reactions

 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

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

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

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

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 Min
Min 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 Ind
Definitions
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 IIA
Sequence V
Sequence IIIA
Fuel -1% S
SD 1968 Models CRC L-38
Sequence IV
Caterpillar L-1
Sequence IIB
Sequence VB
Caterpillar IH
Sequence IIIB
Falcon Rust
SE 1972 Models CRC-L-38
Sequence IIID
Sequence IIB
Sequence VC
Sequence IIIC
Sequence VD
SF 1980 Models CRC-L-38
Sequence IIIE
Sequence IID
Sequence VD
Sequence IIID

API Automotive Gasoline Engine
Service Categories – “SA, SB,…”
Definitions
SG 1989 Models CRC-L-38
Sequence VE
Sequence IID
Caterpillar IH2
Sequence IIIE
SH 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 Sequence IIIE
SL 2001 Models Sequence IIIF
Sequence VIII
Sequence IVA Sequence VG
SM 2004 Models Sequence IIIG
Sequence 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-2104A
Supplement 1
CRC L-38 Caterpillar L-1 Fuel – 0.4% S
CC MIL-L-2104B
MIL-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/E
2 stroke Hvy Dty
CRC L-38 Caterpillar 1 G2 Detroit Diesel
6V53T
CE None CRC L-38
Mack T-6
Caterpillar 1 G2
Mack T-7
Cummins NTC 400
CF None CRC L-38 Caterpillar 1M-PC

API Automotive Diesel Engine
Service Categories – “CA, CB,…”
Spec
CF-2 None CRC L-38 Detroit Diesel 6V92TA Caterpillar 1M-PC
CF-4 None CRC L-38
Mack T-7
Cummins NTC-400 Caterpillar 1K
CG-4 None CRC L-38
Mack T-8
Sequence IIIE
RFWT
Caterpillar 1N
CH-4 None Mack T8E
RFWT
Sequence IIIE
Mach T-9
Caterpillar 1P, 1K
Cummins M 11
CI-4 None RFWT
EOAT
Cummins M11 EGR
Mack T-8E, T-10
Caterpillar 1R, 1K
Sequence IIIF
CI-4Plus None RFWT
EOAT
Cummins M11 EGR
Mack T-8E, T-10,T-11
Caterpillar 1R, 1K
Sequence 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 - 475
00 400 - 430
0 355 - 385
1 310 - 340
2 265 - 295
3 220 - 250
4 175 - 205
5 130 - 160
6 85 - 115

Hussam Adeni
Thank you
Lube.specialist@gmail.com

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