Académique Documents
Professionnel Documents
Culture Documents
Function of a Lube
Base Oils
Lubricant Characteristics
Additives
Engine Fundamentals
When Lubrication Fails
Specifications
Fuel Economy & Emissions
Alternative Fuels
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1. Function of a lube
Lubricants: Friction & Wear
1. Function of a lube
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Why do we use Lubricants?
REDUCE FRICTION
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What is Friction?
STATIC
KINETIC..
ROLLING..
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What is wear?
Types of wear:
Abrasive
Adhesive
Corrosive
Pitting
Cavitation
Asperity contacts –
high coefficient
of friction
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How do we reduce friction and wear with lubricants?
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Lubrication Regimes
Increasing
Elasto-hydrodynamic
severity
Thin film or Mixed
Boundary
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Hydrodynamic regime
Hydrodynamic Pressure
Stationary Surface
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Hydrodynamic regime
Low Load
High speed
Laminar
Flow
Static
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Mixed regime
High load
Low speed
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Boundary
Lubricant Film
Surface Contact
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Elasto-hydrodynamic
Example:
Loaded Gears
Extremely thin film between two surfaces due to high
loads – one or both of the surfaces undergo elastic
deformation
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The Stribeck curve
Lubrication Regimes
Boundary
Mixed
Hydrodynamic
Friction
Minimum Friction
Film Thickness
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Other Functions of a Lubricant
1. Function of a lube
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Other Functions of a Lubricant
Cleans Seals
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Protects
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Cools
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Contains
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Cleans
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Seals
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2. Refining & Base Oils
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Typical Engine Oil Composition
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Base Oils
2. Refining & Base Oils
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Where do base oils come from?
Carbon 84%
Hydrogen 14%
Sulphur 1-3%
Nitrogen <1%
Oxygen <1%
Metals <1%
Salts <1%
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Crude Oil - Classification
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Crude Oil Hydrocarbon type
Paraffinic
Aromatic Naphthenic
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Crude Oil Sources
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Producing Base oils from Crude
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Fractional Distillation
Gasoline
Light diesel
Heavy diesel
Mineral base oil
Asphalt
Crude oil Distillation unit
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Mineral & Synthetic Base Oils
Synthetic
Ethylene Synthesis (PAO)
base oil
Hydro-cracker Synthetic*
base oil
De-waxing Highly
Mineral refined
base oil Unit
mineral
base oil
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Base Oil Classification
Synthetics Group V
Group IV
Synthetics*
Group III
Minerals Group II
Group I
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API Base Stock Grouping
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Mineral vs. Synthetic
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Synthetic Base Oil
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Part Synthetic Products
Mineral Synthetic
Mineral
Part Synthetic
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Synthetic Performance
2. Refining & Base Oils
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Synthetic Performance
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Cleanliness
Loss of Boost,%
1.5 15
1 10
0.5 5
0 0
Mineral Part Full
synthetic synthetic
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Cleanliness
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Durability
Typical piston
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Wear Control
Wear, nm
2000
Mineral Synthetic
1500
1000
500
0
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Low temperature performance
100
90
Total Shifting force, N
80
70
60
50
40
30
20
10
0
25°C -15°C
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Fuel Efficiency
4
% Fuel Economy vs 15W40
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3. Lubricant Characteristics
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Contents
Viscosity
Multigrade oils
Measuring viscosity
Viscosity index
Other Attributes
Volatility
Sulphated Ash / TBN / TAN
Foam
Pour point
Flash point
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Viscosity
3. Lubricant Characteristics
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What is Viscosity?
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Viscosity
Temperature
Low High
Viscosity varies as the
fluid temperature changes
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Viscosity Classification
Thinner Thicker
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Viscosity Classification
SAE 40 Range
20 30 40 50 60
Thinner Thicker
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Traditional monogrades
Low viscosity
SAE 10W
for winter
SAE 20W
(Thin)
SAE 30
High viscosity
SAE 40 for summer
SAE 50 (Thick)
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Multigrade oils
SAE 10W - 30
Low Temp High Temp
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Monograde v Multigrade
10W-30
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Viscosity Index
Viscosity (log)
1000
800
600
400
200
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SAE J300 - Viscosity Grades Engine Oils
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Kinematic Viscosity
KV100
°C
D
A KV40
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Dynamic Viscosity - HTHS
150°C
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Cold temperature viscosity – CCS & MRV
°
C
-C
Test temperatures
Shear Rate 104 s-1 from 0 to -35°C
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Comparing different scales
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The trend to lower viscosity oils
Mono
50
Viscosity 10W-40
Grade
0W-30
5W-30
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Other Attributes
3. Lubricant Characteristics
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Volatility - Noack
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TAN and TBN
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Sulphated Ash
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Foam
Oil’s resistance
to foaming
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Pour Point
Room Temperature
- 27°C
- 30°C
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Flash Point
HEAT
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4. Additives
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Typical Engine Oil Composition
Tailored formulations
Differing treat rates
(percentages)
Base Oils 80% Differing additive types
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Engine Oil Additives
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Contents
Modifiers
VI improvers
Pour point depressants
Oil Protectors
Anti Oxidants
Anti Foam
Surface Protectors
Detergents
Dispersants
Anti Wear
Friction Modifiers
Extreme Pressure
Corrosion inhibitor
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Modifiers
4. Additives
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Engine Oil components
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Viscosity Index Improvers
Role
Reduce change in viscosity with
temperature
Function
Allow thinner base oils to be used
whilst maintaining viscosity at high
temperatures
Other names
Viscosity Modifier (VM)
Polymer
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Viscosity Index Improvers – Mode of Action
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Viscosity Modifier - Polymer Structures
Ethylene-Propylene (OCP):
Polymethacrylate:
O O O O O O O
OR OR OR OR OR OR OR
Styrene-Isoprene:
Styrene-Isoprene Star:
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Viscosity Index Improver Performance
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Pour Point Depressants
Role
Allow oil to flow freely at extremely low
temperatures
Function
Keep oil in a liquid phase and suppress
crystallisation
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Pour Point Depressants – Mode of Action
Characteristics
Prevent large wax crystals forming at low temperature
Promote formation of small, free moving particles
Large 3D Small
Crystals Crystals
Crystal formation
interrupted
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Pour Point Depressant Performance
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Oil Protectors
4. Additives
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Anti-Oxidants
Role
Slow down degradation of oil as a
result of exposure to high temperature
Function
Prevent oxidative thickening
Maintain acid neutralisation capability
of the oil
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Anti-oxidants – Mode of Action
Characteristics
React with aggressive
compounds in the oil to make
them inactive
Slow the natural rate of oxidation
+ + = Oxidation
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Anti-Oxidant Performance
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Anti-Foam
Role:
Prevent foaming of the oil in
operation
Function:
Reduce air entrainment
Encourage formation of large
bubbles
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Antifoam Agents – Mode of Action
Performance
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Surface Protectors
4. Additives
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Detergents
Role:
Surface cleaning agents
Functions:
Maintain cleanliness of internal engine
parts
Reduce deposit build up
Neutralize acids
Sulfur and Nitrogen acids from
combustion
Organic acids from oxidation
Inhibit oxidation (2nd function)
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Detergents Mode of Action
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Detergent Performance
Piston Deposits
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Dispersants
Role:
Stabilise lubricant contaminants
Functions:
Keep insolubles in suspension
Maintain engine cleanliness
Minimise viscosity increase from soot
loading
Prevent contaminants from interacting
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Dispersant Mode of Action
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Dispersant Mode of Action
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Dispersant performance
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Sludge
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Anti-wear Agents
Role:
Surface protector
Function:
Reduce wear
Prevent metal to metal contact
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Anti-wear Mode of Action
Characteristics
Activated at high temperatures/loads
Mechanism
Chemical adsorption of additive onto the ZDDP
metal surface
Acts as sacrificial barrier
Heat
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Anti-Wear Performance
Sliding contact
Cam zone
Follower
Most effective in valve-
train sliding contact
Spring
Poppet valve
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Friction Modifiers
Role:
Modify the frictional properties of a
lubricant
Function:
Reduce or increase friction
Reduce wear (2nd function)
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Friction Modifiers – Mode of Action
Characteristics
Surface active
Low resistance to shear
Physical separation of
surfaces (good compressive
strength)
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Friction Modifier Performance
Reduced friction
Increased fuel economy
Increased power
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Corrosion Inhibitors
Role:
Prevent internal corrosion of the
engine components
Function:
Neutralise acids
Prevent acids and water attacking
component surfaces
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Corrosion Inhibitor – Mode of Action
Characteristics
Surface active Water
Protective film on metal surface
Work at a range of temperatures
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Corrosion Inhibitor Performance
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Extreme Pressure (EP) Agents
Chlorine / Sulfur /
Sulfur-Phosphorus
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5. Engine Fundamentals
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Course Content
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Typical view of an engine2
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Engine Layout
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Engine Layout
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The 4 Stroke Cycle
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Fuels & Combustion
5. Engine Fundamentals
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Diesel v Gasoline
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Gasoline vs Diesel
Gasoline Diesel
Quieter Better fuel economy
Lighter Heavier
High Power High Torque
Lower initial cost Longer life
Catalyst emissions control Good reliability
Catalyst and particulate
trap emissions control
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Fuel Injection
5. Engine Fundamentals
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Fuel Injection
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Direct & Indirect Injection
Gasoline Diesel
Indirect Indirect
Still in common use Almost obsolete
Cheap Uses a pre-chamber not
Low pressure port FI
Direct Direct
Emerging technology Dominant technology
Greater efficiency Greater efficiency
High pressure Very high pressure
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Component Lubrication
5. Engine Fundamentals
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Typical lubrication system
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Engine Bearings
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Con. Rod (Big & Little End)
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Piston Assembly
Lubricant Requirements
Side Skirts
Ring grooves
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Piston, Rings & Liner
°
800°
C Piston gets hit by the hot and
expanding gases.
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Piston, Rings & Liner
Cylinder wall is
specially roughened
(honed) to hold oil.
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Oil Control Ring
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Valvetrain
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Valvetrain - Camshaft
OHC Arrangement
Camshafts, lifters and rockers
control the opening and closing
of the valves. Cams and lifters
and rockers are in mechanical
contact with each other and the
valves.
Camshafts and lifters and
rockers need lubrication at their
contact area where forces can
be very high and boundary
lubrication is typical.
ZDDP anti-wear additive
important to protect cam lobes
and lifters.
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Valvetrain - Valves
Cam
Valves control the
flow of fresh air and
exhaust gases into
and out the engine
cylinders.
Follower
Spring
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Forced Induction
5. Engine Fundamentals
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Forced Induction
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Turbocharger
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Turbocharging
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Supercharging
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Forced Induction – Lube Impact
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Engine Development
5. Engine Fundamentals
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Engines have become
Smaller Cheaper
Faster Cleaner
Multi-valve components
Small sumps
Turbochargers
Low emissions
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6. When Lubrication Fails
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What can happen to an Oil In service ?
Fuel
Deposits Physical changes
cause
Water Chemical changes
Antifreeze
leads to
Acids
Wear Metals
Viscosity Breakdown
Thermal Breakdown
Deposit drop-out
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Viscosity Breakdown
Result:
Reduced film thickness
Increased wear
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Thermal Breakdown
Oil thickening
(oxidation)
Oil loss
(evaporation)
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Oil Thickening
Good Poor
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Sludge & Varnish
Sludge Varnish
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Sludge
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Sludge
Results:
Blocked oil ways
Blocked oil pickup
Blocked filter
Loss of lubrication
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Soot
Diesel engines
Unburned fuel
Dispersant saturated
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Oil Loss - Evaporation
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What can happen to an Oil In service ?
Fuel
Deposits Physical changes
cause
Water Chemical changes
Antifreeze
leads to
Acids
Wear Metals
Viscosity Breakdown
Thermal Breakdown
Deposit drop-out
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Used Oil Analysis
6. When Lubrication Fails
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Used Oil Analysis
Physical
Viscosity & visual
Chemical
TAN, TBN
Wear Metals & Additive content
Contaminants – fuel, water,
antifreeze
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Physical Testing
Visual appearance
colour, fallout, sludge, debris,
Kinematic Viscosity 100°C
determines the high temperature viscosity grade
CCS, MRV
determine low temperature viscosity grade (W grade)
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TAN and TBN
8
Acid / Base
g/g KOH)
Difference
TAN
TBN
/ TBN (m
6
TANTAN/TBN
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Chemical Testing
Additives
Wear
Contamination
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Chemical Testing
1.2e+07
Abundance
1e+07
9000000
8000000
Method: 7000000
Gas 6000000
Chromatography 5000000
(GC) 4000000
biofuel
3000000
1000000
Time (min)
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Chemical Testing
Water
Sludge
precursor
Method
Karl Fischer
Karl Fischer
Oven
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Chemical Testing
Antifreeze
Important for sludge
inquiries.
Method
Glycol tablet test
ICP metals
Water
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7. Specifications
Industry Specifications
7. Specifications
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Specs & Guidelines
ATIEL Code of
API 1509 Engine Oil Practice
Licensing and (European
Certification System Lubricants
Industry)
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API – Gasoline
SA SJ SL,SM
Straight mineral oil no additives Highly additised base oil, mineral, part or
fully synthetic
Increasing Performance Standards
CF CF-2
CA CD CJ-4
Increasing Performance Standards
Prefix C ~
Compression Ignition
Linked to API
API “Donut”
ILSAC “Starburst”
Latest ILSAC spec
is GF-4
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ACEA
Those performance criteria that are more severe than for API:
Viscosity Control
Volatility
Thermal Stability
Wear Protection
Seal Performance
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ACEA
Heavy Duty
Light Duty Vehicles Diesel Vehicles
A B C E
A1 A3 B1 B3 C1 C2 E2 E4
A5 B4 B5 C3 C4 E6 E7
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Testing – ACEA
Bench tests:
Viscosity – high and low temp Engine Tests
Shear stability What is measured Name of engine used
High temp high shear
Evaporation loss Wear Peugeot TU3M,
Sulphated ash OM602A, Cummins ISM, Mack T10
Sulphur
Phosphorus Fuel economy M111
Chlorine
Oil elastomer/seals Sludge Sequence VG, M111
Foam tendency
Filterability Cleanliness of pistons VW Tdi, Peugeot TU5, OM364LA, OM441LA
Deposit tests – deposits & varnish
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Emissions Legislation
Kyoto Protocol
Started discussing GHG’s Berlin 1995
2 ½ yrs to agree!
Kyoto meeting agreed limits Dec.1997
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CO2 levels increasing
370
360
350
340
330
320
310
58 62 66 70 74 78 82 86 90 94 98 02
Man-made
CO2 Emissions 20051
Power Generation
35% Transportation,
20%
Environment
Cost of motoring
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Fuel economy – lube impact
Mono
50
10W-40
Viscosity
Grade 0W-20 G/H
0W-30
5W-30 5W-20 G
0W-30 D
5W-30 D
By-products of combustion
Contribute to smog
Increase heart/lung problems (NOx)
Potential carcinogen (PM)
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Emissions limits drive Lubes specs
API CI-4
EURO III EURO IV API CJ-4 EURO V PC-11 EURO VI
Plus
ACEA E4 ACEA E6 ACEA E6
DH-2
Russia – Imported
vehicles must meet
EURO II minimum EURO 3 EURO 4
EURO 3 EURO 4
Mexico – Since Beijing type Beijing
type
2003 Imported emissions emissions
vehicles must EURO 3 legislation EURO 4
legislation
meet EURO III - Brazil
India* - Brazil India*
minimum
02 03 04 05 06 07 08 09 10 11 12
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Why does emissions legislation affect the lubricants industry?
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ATDs
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SAPS - Sulphated Ash, Phosphorus & Sulphur
VI improver
Antioxidant Sulphur
Sulphur
Anti foam Detergents Ash
Phosphorus
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Clean Performance Technology
Detergent
(~16%
Anti-wear
(~5%)
Detergent (~33)
Anti-oxidant
(~4%) Dispersant
Dispersant (~50%)
(~55%)
Clean
Performance
Technology
Anti-wear (~25%)
(~10%)
Anti-oxidant
(~2%)
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SCR system
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Summary of Aftertreatment Technologies
Urea infrastructure
Good fuel economy No special requirements identified
SCR Low running cost
Not good for city drive cycle
yet2
Size of device
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Lubricant disposal
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