The Basics of Lubricants and lubrication

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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
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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
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Methods of lubrication
Two main methods

cont..

Hydrodynamic lubrication Boundary lubrication

Boundary lubrication Occurs when Hydrodynamic lubrication fails. By adsorption or chemical reaction
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Types of Lubricant - Physical

Liquid
Solid Semi solid Gases

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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
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Typical lubricants - Application

Engine oils

Gear Oils
Turbine Oils Hydraulic Oils Metal working oils Cutting oils Forming Oils Rust preventives
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Typical lubricants - Application

Heat Transfer Oils

Heat Treatment Oils Quenching Oils Tempering Oils Refrigeration Oils

Rubber Process Oils

Ink process Oils

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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
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Function of a lubricant
Lubricate - Reduce friction
Cooling - Heat transfer Cleaning - Detergency Noise pollution - dampening Sealing prevent leakage

Protection prevent wear

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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

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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.

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Cleaning
Cleans carbon and varnish deposits
Flushes the entire system removing
Soot Deposits Acids Wear products Moisture

Removes external contaminants dust,

moisture (external)

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Noise reduction
Reduce noise By preventing metal to metal contact
Dampens noise As between camshaft and tappet

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Sealing
Oil film Between piston ring and liner Helps in creating a gas tight seal

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Protection
Protection against acids and

moisture

Very important to increase life of

component and equipment

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Properties of lubricants
Kinematic viscosity
Viscosity index Pour Point Flash Point Total Base Number (TBN)

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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 40C and 100C Measured in Centi Stokes (CSt)
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Kinematic Viscosity Recommendations

Low Viscosity oils used High speeds Low pressure Low temperature
High Viscosity oils used Low speeds High pressure High temperature
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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
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Properties of lubricants
Pour Point Lowest temperature at which the fluid will flow Indicates lowest operating temperature Measured in C

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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
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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

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Lab Tests - for lubricants

Kinematic viscosity Viscosity index Pour Point Flash Point

Total Base Number (TBN)
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ASTM ASTM ASTM ASTM ASTM ASTM

D D D D D D

445 2250 97 92 (COC) 93 (PMCC) 664

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What are additives Lubricant additives

classified on their functional capability Enhance existing property Suppress undesirable property Impart new property

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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

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Surface Protective additives

Anti wear and EP Agent Corrosion & Rust inhibitor Detergent Dispersant Friction modifier

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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

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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
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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

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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
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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

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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

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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.

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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

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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

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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

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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

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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
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2000
1500

ISO VG

AGMA

1500
1000 8A

SAE Eng ine Oils

SAE Gear Oils

10000

5000 1000 800

680 8

140
5000 3000 3000

Viscosity Grade Classification Systems 400

ISO Industrial Oils
cSt @ 40C
300 200 150

600 500

460

2000
2000
320 6 50 220 150 5 40

90

AGMA Industrial Gear Oils

cSt @ 40C

4 3

1000

1000

100

30

85W 80W

500 500 400 400 300

SAE Engine Oils

100 80

68 46

2 1

20

cSt @100C, cP @150C 60 50 cP @ -10C to -40C 40

30

300 200

75W
15W

200

32

SAE Gear Oils

cSt @100C cP @ -12C to -55C

100
10W 22 8 5W&0W

20 15 10
cSt @ 40C

100
60

15

10

60

SUS @ 100F

Lubricant - Specifications

Crankcase oils - SAE numbers Crankcase oils - Performance levels Crankcase oils OEM Specifications Viscosity classification

Grease specification

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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

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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
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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
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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
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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

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SAE Crankcase Oil - Viscosity classification Winter Service

SAE
Viscosity Grade
Low temp viscosities High temp viscosities Max. Temp for Vis. at 100C, Engine cranking High shear (cP) 150C Max. cPs at Temp pumping viscosity cSt of 60,000 cP(C) (C) Min Max & 106 S-
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

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3.8 3.8 4.1 5.6 5.6 9.3

--

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SAE Crankcase Oil - Viscosity classification Summer Service

SAE
Viscosity Grade

Low temp viscosities High temp viscosities Max. Temp for Vis. at 100C, cSt Engine High shear pumping (cP) 150C & cranking Max. viscosity of Min Max 106 S- Min cPs at Temp 60,000 cP(C) (C)

Summer Service 20
-------

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5.6 9.3 12.5 12.5 16.3 21.9

<9.3 <12.5 <16.3 <16.3 <21.9 <26.1

2.6 2.9 3.5 3.7 3.7 3.7

30 40 40 50 60

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API Automotive Gasoline Engine Service Categories SA, SB,

Category

SA

Related Ind Definitions Straight Min None Inhibited only CRC L-4 1964 Models 1968 Models

Engine Test Requirements

SB SC SD
SE SF

Sequence IIA Sequence IIA Sequence V

Sequence IIIA
Sequence IIIA Fuel -1% S

CRC L-38 Sequence IV

CRC L-38 Sequence IIB Sequence IV Sequence VB Caterpillar L-1 Caterpillar IH

Sequence IIIB Falcon Rust

Sequence IIIC Sequence VD Sequence IIID

1972 Models
1980 Models

CRC-L-38 Sequence IIB Sequence IIID Sequence VC

CRC-L-38 Sequence IID Sequence IIIE Sequence VD
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API Automotive Gasoline Engine Service Categories SA, SB,

Category

SG SH SJ

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
CRC-L-38 Sequence VE

Sequence IID

Sequence IIIE

Category SA, SB, SC, SD, SE,SF,SG,SH have been declared as obsolete.

1997 Models 2001 Models 2004 Models

Sequence IID

Sequence IIIE

SL
SM

Sequence IIIF Sequence IVA Sequence VIII Sequence IIIG Sequence IVA Sequence VIII

Sequence VG
Sequence VG

Category SJ, SL, SM, are currently valid.

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API Automotive Diesel Engine Service Categories CA, CB,

Category

CA CB CC

Related US Mil spec MIL-L-2104A

Engine Test Requirements CRC L-38 L-38 L-38 L-38 Caterpillar L-1 Caterpillar L-1 Sequence IID Caterpillar I G2 Fuel 0.4% S Fuel 0.4% S Caterpillar IH2

CD
CD-II CE CF

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 None None

L-38

CRC L-38 Mack T-6 CRC L-38

Caterpillar 1 G2 Detroit Diesel 6V53T Caterpillar 1 G2 Cummins NTC 400 Mack T-7
Caterpillar 1M-PC
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API Automotive Diesel Engine Service Categories CA, CB,

Category

CF-2 CF-4 CG-4

Related Ind Engine Test Requirements Spec None CRC L-38 Detroit Diesel 6V92TA Caterpillar 1M-PC None None None 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 RFWT EOAT Cummins M11 EGR Mack T-8E, T-10 Caterpillar 1K Caterpillar 1N

CH-4
CI-4 CI-4Plus

Caterpillar 1P, 1K Cummins M 11

Caterpillar 1R, 1K Sequence IIIF

None

RFWT EOAT

Cummins M11 EGR Caterpillar 1R, 1K Mack T-8E, T-10,T-11 Sequence IIIF

CA to CE obsolete; CF onwards are currently valid

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ISO 3448 Kin Vis - CSt 40C vs SUS 100F (40C)

Midpoint Minimum Maximum SUS 100F

VG 2 VG 3

2.2

1.98

2.42

VG VG VG VG VG VG VG

5 7 10 15 22 32 46

3.2 4.6 6.8 10 15 22 32 46

2.88 4.14 6.12 9 13.5 19.8 28.8 41.4

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3.52 5.06 7.48 11 16.5 24.2 35.2 50.6

60

75 105 150 215

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ISO 3448 Kin Vis - CSt 40C versus SUS 100F (40C)
Midpoint Minimum Maximum SUS 100F

VG 68 VG 100

68

61.2

74.8

VG VG VG VG VG VG VG

150 220 320 460 680 1000 1500

100 150 220 320 460 680 1000 1500

90 135 198 288 414 612 900 1350

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110 165 242 352 506 748 1100 1650

315 465

700 1000 1500 2150 3150 4650 7000

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National Lubricating Grease Institute - NLGI Numbers

NLGI Grade Number ASTM worked penetration 77F (25C)

000 00 0 1 2

445 400

475 430

3 4 5 6
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355 310 265 220 175 130 85

- 385 - 340 - 295 - 250 - 205 - 160 - 115

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Thank you

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