1. Evonik’s Performance
Evonik’
Envelope of Fuel- and
Cost-efficient Solutions
for Your Driveline Fluids
Torsten Stoehr, Boris Eisenberg,
Justin Mills, Thorsten Bartels,
Aidan Rose

2. 1. Mission Fuel Economy
2. VISCOPLEX® 12-199 Comb Polymer for
Your Fuel Economy ATF
3. VISCOBASE® 11-522 is
Your Cost-efficient Alternative for Axle Oils
2013-04-20 | Evonik’s Performance Envelope ...
Page | 2

3. 1. Mission Fuel Economy
2. VISCOPLEX® 12-199 Comb Polymer for
Your Fuel Economy ATF
3. VISCOBASE® 11-522 is
Your Cost-efficient Alternative for Axle Oils
2013-04-20 | Evonik’s Performance Envelope ...
Page | 3

4. Our Joint Global Challenge:
Fleet Average CO2 Emissions
• European targets:
• European targets:
� 2015: 130g/km
� 2020: 95g/km
2020: 95g/km
• ∆ = 35g/km
• ∆ = 35g/km
� 27%
27%
� 1.5L/100km
5.6L/100km
4.1L/100km
Global Comparison of Light-Duty Vehicle Fuel Economy/GHG Emissions Standards, ICCT, June 2012
2013-04-20 | Evonik’s Performance Envelope ...
Page | 4

5. Evonik’s Fuel Economy Solutions
Evonik’
for the Automotive Industry
Aerodynamic Panels
Light Weight
Engine
Transmission
Axle
Drivetrain & Lubricant
2013-04-20 | Evonik’s Performance Envelope ...
Roll Resistance
Page | 5

6. Drivetrain Trends
End-consumer Perspective
End-consumer Perspective
Socio-economic View
Socio-economic View
•
•
•
•
•
•
Global warming
Global warming
Reduce dependency on fossil fuels
Reduce dependency on fossil fuels
CO2 emission reduction
CO2 emission reduction
OEM Trends
OEM Trends
All season & all climate
All season & all climate
Long drain intervals � fill-for-life
Long drain intervals � fill-for-life
Improved driving/shifting comfort
Improved driving/shifting comfort
Reduced operating costs
Reduced operating costs
Reduced noise
Reduced noise
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Low viscosity lubricants
Low viscosity lubricants
Reduced low temperature viscosity
Reduced low temperature viscosity
Improved wear/fatigue protection
Improved wear/fatigue protection
Mechanical stability
Mechanical stability
Tailored friction performance
Tailored friction performance
Thermal/oxidative stability
Thermal/oxidative stability
Low SAPS
Low SAPS
Fuel
Economy Requirements
Lubricant Requirements
Lubricant
• New generation MT, 7/ 8-speed
• New generation MT, 7/ 8-speed
AT, DCT and CVT
AT, DCT and CVT
• Higher torques (at low speeds)
• Higher torques (at low speeds)
• Smaller transmissions
• Smaller transmissions
• Higher temperatures
• Higher temperatures
• Emission control (N, P, S)
• Emission control (N, P, S)
2013-04-20 | Evonik’s Performance Envelope ...
•
•
•
•
•
•
•
•
•
•
Page | 6

7. contracted
VII
Log Log viscosity
Lubricant with its Viscosity Index
Improver as Crucial Design Element
ba
se
oil
(VI
ligh
=1
t ba
00
se o
)
il +
VII
(VI=
200
)
expanded
VII
Log T
efficiency advantage via
reduced viscosity
(internal friction) @ low T
2013-04-20 | Evonik’s Performance Envelope ...
maintain viscosity
@ high T to avoid
wear/fatigue
Page | 7

8. Some Definitions using Parameter
“Molecular Weight”...
Weight”
low
� Low PSSI
� Mw as key design
parameter…
Molecular
Weight
high
� Flat V/T curve
- High VI
- Low BF-40
� Low treat rate for
fixed KV100
� …within performance window
of given polymer chemistry
2013-04-20 | Evonik’s Performance Envelope ...
Page | 8

9. Polymer Chemistry
Polyolefins
Ester-funtional polymers
� Poly(isobutylene) PIB
� Olefin copolymers OCP
� Hydrogenated styrene / diene
copolymers HSD
� Poly(α-olefin) PAO
� Poly(alkyl methacrylate) PAMA
� Styrene / fumarate copolymers
� α-Olefin / fumarate copolymers
-Olefin
CxHy
� Low treat rate
2013-04-20 | Evonik’s Performance Envelope ...
Polymer
Chemistry
C=O
I
OR
� Flat V/T curve
� Low PSSI
Page | 9

10. PAMA VII as Crucial Design Element
for Fuel Economy
1. Reduced internal friction at low
temperatures
3. Friction-modifier application in
mixed lubrication regime
viscosity
2. Dispersancy of oxidation
products to avoid viscosity growth
ba
se
oil
PAM
A
Transmission
Axle
EH L
PAMA
boundary
mixed
Engine
friction coefficient
temperature
PAMA
hydrodynamic
s
ard ies
tow osit
d
ren r visc
t
e
low
speed x viscosity / load
2013-04-20 | Evonik’s Performance Envelope ...
Page | 10

11. Advances in Transmission
Technology
8-speed AT
MT
DCT
CVT
2013-04-20 | Evonik’s Performance Envelope ...
Page | 11

12. Performance Requirements
Addressable by Evonik Components
MTF ATF
CVTF
DCTF
Belt/chain Toroidal
Main performance
Synchronizer performance
Anti-shudder durability
o
Steel-on-steel friction coefficient
Dry
o
o
Wet
o
o
o
Traction property
o
Basic performance
V/T + low T performance
�
�
�
�
�
�
Shear stability
�
�
�
�
�
�
Oxidation/thermal stability
o
o
o
o
o
o
o
o
o
o
Clutch friction stability
Wear protection
�
�
�
�
�
�
Fatigue protection
�
�
�
�
�
�
Defoaming
�
�
�
�
�
�
Materials compatibility
o
o
o
o
o
o
Source: Jatco
2013-04-20 | Evonik’s Performance Envelope ...
Page | 12

13. 1. Mission Fuel Economy
2. VISCOPLEX® 12-199 Comb Polymer for
Your Fuel Economy ATF
3. VISCOBASE® 11-522 is
Your Cost-efficient Alternative for Axle Oils
2013-04-20 | Evonik’s Performance Envelope ...
Page | 13

14. contracted
PAMA
Log Log viscosity
Comb Polymers:
How Does it Work?
base oil
expanded
PAMA
Log T
collapsed
comb
fuel economy via
reduced viscosity
@ low T
2013-04-20 | Evonik’s Performance Envelope ...
maintain viscosity
@ high T to avoid
wear/fatigue
expanded
comb
Page | 14

15. Global Trend to Low Viscosity ATF
Source: Infineum Insight 49 (March 2011), p. 9
2013-04-20 | Evonik’s Performance Envelope ...
Page | 15

16. ATF Formulations
6.0cSt
Conventional
PAMA
6.0cSt
VISCOPLEX®
12-199 (Comb)
4.5cSt
VISCOPLEX®
12-199 (Comb)
VII [%]
8.5
5.7
3.5
VISCOPLEX® 1-180 [%]
0.3
0.3
0.3
DI package [%]
15.0
15.0
15.0
Nexbase 3030 [%]
76.2
79.0
30.0
Nexbase 3020 [%]
-
-
51.2
KV100 [mm²/s]
6.03
6.02
4.48
5.46
KV40 [mm²/s]
28.4
24.7
17.1
26.0
VI
166
210
193
152
BF [mPas]
10,200
6,600
2,900
7,900
PP [°C]
-48
-48
< -48
-45
KV100KRL20 [mm²/s]
5.71
5.70
4.35
5.35
KV100 loss [%]
5.3
5.4
2.9
2.1
PSSI
18
18
15
-
2013-04-20 | Evonik’s Performance Envelope ...
5.5cSt
Hyundai
SP-IV FF/SF
Page | 16

17. Fuel Economy Study at ISP
• 6-speed AT Hyundai ix35 = Tucson (120kW @ 6200rpm)
4
• Test sequence (4 cycles each, 5 oil flushings in between):
� 5.5cSt FF/SF (1)
� 6.0cSt Conventional
� 6.0cSt Comb
� 5.5cSt FF/SF (2)
� 4.5cSt Comb
� 5.5cSt FF/SF (3)
• Chassis dynamometer (MAHA-AIP)
� load: ± 0.5%, speed: ± 0.08km/h
• Gas analyzer (Horiba)
� CO/CO2, HC (and NOx)
� Constant volume sampling (CVS) acc. to ECE R83
• EU5 Reference Fuel
• NEDC standard deviation: ± 0.28% (12 cycles 5.5cSt FF/SF)
2013-04-20 | Evonik’s Performance Envelope ...
Page | 17

18. New European Driving Cycle (NEDC)
80
150
ECE* 3+4
Urban Driving
Cycles
EUDC Extra
Urban Driving
Cycle
60
100
40
5.5cSt FF/SF (2)
50
20
0
0
200
400
600
800
1000
Vehicle speed [km/h]
Transmission oil temperature [
]
ECE* 1+2
Urban Driving
Cycles
0
1200
Time [s]
* ECE = Economic Commission for Europe
2013-04-20 | Evonik’s Performance Envelope ...
Page | 18

19. Fuel Consumption by Sub-cycle
12
.8
12 7
.8
12 3
.5
3
14
6.0cSt Conventional
6.0cSt Comb
4.5cSt Comb
5.5cSt FF/SF
12
10
8.
62
8.
52
8.
49
8.
54
11
10
.2
10 9
.1
10 9
.1
2
9
88
6.
78
6.
83
8
6.
Fuel consumption [L/100km]
13
7
• Comb polymer (in
parallel to KV100
lowering) reduces
fuel consumption
in NEDC and its
ECE sub-cycles
• In EUDC, the 4.5cSt
fluid shows
increased fuel
consumption due to
mixed lubrication
6
ECE 1+2
2013-04-20 | Evonik’s Performance Envelope ...
ECE 3+4
EUDC
NEDC
Page | 19

20. NEDC Fuel Economy
2.0
2.0
1.5
NEDC FE vs. 5.5cSt
SF/FF [%]
NEDC FE vs. 6cSt
Conventional [%]
1.6
1.2
1.0
0.5
0.0
6.0cSt Comb
4.5cSt Comb
• 6.0cSt Comb delivers 1.2% FE vs
6.0cSt Conventional
• Lowering KV100 to 4.5cSt results
in 1.6% FE totally (mixed
lubrication!)
2013-04-20 | Evonik’s Performance Envelope ...
1.5
1.0
0.5
0.3
0.0
6.0cSt Comb
• 6.0cSt Comb delivers 0.3% FE vs
5.5cSt FF/SF, but at higher KV100
implying higher wear and fatigue
protection
Page | 20

21. 1.2% FE Improvement: Savings in
the Transmission Value-chain
Savings at the OEM
• 2015 target:
130 gCO2/km
• 2020 enacted: ∆ = 35 gCO2/km
•
Penalty:
95€ per gCO2
95€
Savings at the end-consumer
• Consumption:
8.62 L/100km
• Drain interval:
100.000 km
• Gasoline price: 1.50 €/L
150 €
150 €
Evonik
Evonik
Contribution
Contribution
150 €
150 €
Fuel Cost
Fuel Cost
Savings
Savings
2013-04-20 | Evonik’s Performance Envelope ...
Page | 21

22. Conclusion
• Reducing fleet average CO2 emissions is our joint global challenge
• Evonik VII are crucial design elements for fuel economy
• Comb VISCOPLEX ® 12-199 delivers 1.2% FE vs conventional PAMA
at same KV100 in NEDC
• Further KV100 reduction results in another 0.4% FE whilst risking
mixed lubrication
• Combs enable you to formulate balanced low vis FE ATF
• From concept to factory fill
• OEM and end-consumer savings of 300€ per transmission
300€
2013-04-20 | Evonik’s Performance Envelope ...
Page | 22

23. 1. Mission Fuel Economy
2. VISCOPLEX® 12-199 Comb Polymer for
Your Fuel Economy ATF
3. VISCOBASE® 11-522 is
Your Cost-efficient Alternative for Axle Oils
2013-04-20 | Evonik’s Performance Envelope ...
Page | 23

24. 75W-140 Formulations
75W-140 w/
VISCOBASE®
11-522
75W-140 w/
PAO100
80W-90 Intertek
Reference
SAE J306 JUN2005
Base stock [%]
47.0
57.0
DI package [%]
4.0
4.0
PAO4 [%]
29.0
19.0
Ester, 3.6cSt [%]
20.0
20.0
KV100 [mm²/s]
25.8
25.3
13.7 (non
stay-in-grade)
13.5-18.5 (80W-90)
24-32.5 (75W-140)
KV40 [mm²/s]
170
183
117
VI
187
171
114
BF [mPas]
89,400 (-40°C)
128,000 (-40°C)
35,900 (-26°C)
<150,000
KV100KRL20 [mm²/s]
24.7
25.0
12.0
13.5-18.5 (80W-90)
24-32.5 (75W-140)
KV100 loss [%]
4.3
1.0
11.8
PSSI
5.1
1.1
2013-04-20 | Evonik’s Performance Envelope ...
Page | 24

25. Bench Testing: MTM Mixed
Lubrication & EHL Modes
0.10
0.05
75W-140 VISCOBASE ® 11-522
75W-140 PAO100
30N
2000mm/s
0.04
120
Friction coefficient
Friction coefficient
0.08
®
®
75W-140 VISCOBASE 11-522
75W-140 PAO100
0.06
25
0.04
30N
50%SRR
0.02
0.00
0.03
25
40
60
0.02
80
100
120
0.01
0.00
1
10
100
1000
Mean speed [mm/s]
10000
0
10
20
30
40
50
SRR [%]
• Note highly resolved y-axes!
• VISCOBASE® 11-522 and
PAO100 show same friction
coefficient in MTM mixed
lubrication and EHL modes
2013-04-20 | Evonik’s Performance Envelope ...
Page | 25

26. Bench Testing:
FZG Efficiency and ARKL
10
80
®
®
75W-140 VISCOBASE 11-522: feff = 0.97
75W-140 PAO100: f eff = 0.97
]
60
6
Temperature [
Torque loss [Nm]
8
20
4
44
90
2
feffciency = 1 -
torque /
temperature,
load stage
100
200
Torque [Nm]
20
75W-140 VISCOBASE? 11-522: Tequ = 62
75W-140 PAO100: T equ = 64
loss
temperature,
load stage
0
0
40
300
0
0
100
200
300
400
Time [min]
• VISCOBASE® 11-522 and
PAO100 show same
performance in FZG
efficiency and ARKL tests
2013-04-20 | Evonik’s Performance Envelope ...
Page | 26

27. GM 900 Axle Efficiency Test
at Intertek
800
28 kW 51 kW
16 kW
600
91 kW
165 kW
#29
Torque [Nm]
#17
Potential
operating
range
400
9 kW
Typical operating
range acc. to CAFE
(Corporate Average
Fuel Economy)
5 kW
200
3 kW
1 kW
0
0
#15
#3
1000
2000
3000
Pinion speed [rpm]
“29/20 Schedule”
Schedule”
• 29 stages over 8 constant power lines, 9 calibration stages outside of window
• 20 stages used for analysis, focus on stages #3, #15, #17, #29
• Each point held for 10 min (efficiency computed from last 5 min)
2013-04-20 | Evonik’s Performance Envelope ...
Page | 27

28. GM 900 Axle Efficiency Test
at Intertek
• GM 4WD/RWD vans & SUVs (Chevy, Buick, GMC, Pontiac, Oldsmobile, Cadillac)
• Efficiency is the power ratio of pinion (input) and differential (output) as
measured by torque meters
• Constant temperature mode (external cooler at 49°C = 120°F) or stabilized
temperature mode
• Test sequence (3 cycles each, intense oil flushing in between):
� 80W-90 (1)
� 75W-140 PAO100 (1)
� 75W-140 VISCOBASE® 11-522
� 80W-90 (2)
� 75W-140 PAO100 (2)
� 80W-90 (3)
• Standard deviation: ± 0.17%rel
(9 cycles 80W-90, severest stage #29,
constant temperature mode)
2013-04-20 | Evonik’s Performance Envelope ...
Page | 28

29. Constant Temperature Mode (49°C)
(49°
100
75W-140 VISCOBASE? 11-522
98.4
75W-140 PAO100
98.4
98.5
98.6
98
Efficiency [%]
96.1
96
96.0
• VISCOBASE®
11-522 and
PAO100 show
same efficiency
throughout all
stages
94
92
91.2
91.3
90
#3 (54Nm,
500rpm)
2013-04-20 | Evonik’s Performance Envelope ...
#15 (54Nm,
2900rpm)
#17 (542Nm,
500rpm)
#29 (542 Nm,
2900rpm)
Page | 29

30. Stabilized Temperature Mode
100
75W-140 VISCOBASE? 11-522
98.6 98.6 98.5
99.0 99.0
75W-140 PAO100
98
97.4
80W-90 Reference
Efficiency [%]
96.3
96
95.3 95.5
94
93.5
92.9 92.9
92
90
120
#3 (54Nm,
500rpm)
#15 (54Nm,
2900rpm)
#17 (542Nm,
500rpm)
#29 (542 Nm,
107 105 105
2900rpm)
Stabilized temperature [
]
100
80
66
58
60
40
66
36
34
54
54
• VISCOBASE® 11-522 and
PAO100 show same
efficiency throughout all
stages
• GM 900 Axle Efficiency
Test discriminates
precisely (80W-90 shows
expected behavior
compared to 75W-140)
51
33
20
0
#3 (54Nm,
500rpm)
2013-04-20 | Evonik’s Performance Envelope ...
#15 (54Nm,
2900rpm)
#17 (542Nm,
500rpm)
#29 (542 Nm,
2900rpm)
Page | 30

31. Spin-loss Experiment
• Torque required to overcome axle
resistance, i.e. the friction due to
� oil churning (splashing) losses
� shaft seal losses
� windage losses
• No load
• Constant temperature at 48.9°C
• Speed range as in 29/20 schedule
• VISCOBASE® 11-522 and PAO100
show same spin-loss induced
torque
4
Spin-loss induced torque [Nm]
• Same axle as in efficiency test, but
use of high precision (low torque)
meters
75W-140
PAO100
75W-140
®
VISCOBASE
11-522
3
80W-90
Reference
2
1
0
1000
2000
3000
4000
Pinion speed [rpm]
2013-04-20 | Evonik’s Performance Envelope ...
Page | 31

32. Oxidative Stability
VISCOBASE® 11-522
+ 0.6% aminic/
as is
phenolic mixed AO
486
BV100 [mPas]
US Steel @121°C
(ASTM D2893-B)
PAO100
101
548 (13%)
536 (11%)
208 (106%)
∆TAN [mgKOH/g]
Pressurized DSC
(ASTM D6186)
Induction time @…
BV100’ [mPas]
0.12
0.0
14.2
…155°C [min]
>120
65
…180°C [min]
>120
<10
…210°C [min]
10
100
80
• VISCOBASE® 11-522
w/o detriments vs
PAO100
TGA weight [%]
140
160
180
60
40
?
75W-140 VISCOPLEX 11-522: 82.1%
75W-140 PAO100: 87.9%
20
0
2013-04-20 | Evonik’s Performance Envelope ...
0
60
120
Time [min]
180
Page | 32

33. Conclusion
• VISCOBASE® 11-522 and PAO100 show same …
� … friction coefficient in MTM mixed lubrication and EHL modes
� … performance in FZG efficiency and ARKL tests
� … efficiency throughout all stages of the GM 900 Axle Efficiency
Test (both in constant and stabilized temperature modes)
� … spin-loss induced torque
• No detriments in oxidative stability
• Last but not least: axle cost credit
2013-04-20 | Evonik’s Performance Envelope ...
Page | 33

34. Summary
VISCOPLEX® 12-199
Comb Polymer for
Your Fuel Economy ATF
VISCOBASE® 11-522 is
Your Cost-efficient
Alternative for Axle Oils
100
75W-140 VISCOBASE? 11-522
98.4
75W-140 PAO100
98.4
98.5
98.6
98
1.2% FE
Efficiency [%]
96.1
96
96.0
94
92
91.2
91.3
90
#3 (54Nm,
500rpm)
2013-04-20 | Evonik’s Performance Envelope ...
#15 (54Nm,
2900rpm)
#17 (542Nm,
500rpm)
#29 (542 Nm,
2900rpm)
Page | 34

35. Disclaimer
This information and all further technical advice is based on our present knowledge and experience. However, they imply no liability or other legal responsibility on
our part, including with regard to existing third party intellectual property rights, especially patent rights. In particular, no warranty, whether express or implied, or
guarantee of product properties in the legal sense is intended or implied. We reserve the right to make any changes according to technological progress or further
developments. The customer is not released from the obligation to conduct careful inspection and testing of incoming goods. Performance of the product described
herein should be verified by testing, which should be carried out only by qualified experts in the sole responsibility of the customer. Reference to trade names used
by other companies is neither a recommendation, nor does it imply that similar products could not be used.
VISCOPLEX® , VISCOBASE® and DynaVIs® are registered trademarks of Evonik Industries AG