Knowledge

General reductions in lubricant viscosities in many machine components mean that the role of lubricant additives in forming tribofilms has become increasingly important to provide adequate surface protection against scuffing. However, the relationship between scuffing and the formation and removal of tribofilms has not been systematically demonstrated. In this study a step-sliding speed scuffing test based on contra-rotation using MTM-SLIM and ETM-SLIM has been employed to observe concurrently tribofilm thickness and the onset of scuffing. The initial sliding speed used was found to significantly affect scuffing performance since it determines the extent to which a tribofilm can form before critical sliding speed conditions are reached. Generally, additives that formed thicker tribofilms, especially ZDDPs and triphenyl phosphate, gave effective protection against scuffing, though their protective tribofilms were progressively removed at higher sliding speeds, eventually resulting in scuffing.

The wear rate of any lubricated contact is dependent on many factors, including, surface roughness, lubricant composition, environment, operating conditions, temperatures, etc. There are also many different wear mechanisms, often operating in parallel. Since wear in itself is not an intrinsic property of a system, different wear tests can give very different results.
Despite their popularity and widespread use, all wear bench test methods all have some shortcomings when used to investigate complex lubricant additive combinations. However sophisticated the test method, they are inevitably unable to directly mimic real lubricated contacts conditions of machine elements. Interpretation of different bench test results can be difficult and misleading conclusions can sometimes be drawn.
A new pure sliding wear test is described which can produce measurable wear within a reasonable period of time. The repeatability and merits of the test method is discussed.

One of the least expensive pathways to achieving improvements in vehicle fuel economy is through changes to engine lubricant viscosity and composition. Driven by ever more stringent emissions regulations, OEMs are therefore requiring engine oils to continue protecting engines at lower viscosities and reduced friction.
Different engine operating conditions represent a range of lubrication conditions, and to better understand the full impact of engine lubrication process, one must understand how oils perform in these conditions. In general, additives in lubricants help to provide the right balance of fuel economy while maintaining durability protection. The focus of the present study is on the hydrodynamic lubrication regime, and the rheological properties of oils were investigated and correlated to their fuel economy performance in different engines, Mercedes Benz OM 501 LA and Detroit Diesel DD13, and driving cycles, WHTC (World-Harmonized Transient Cycle) and modal.

The replacement of traditional mineral oil lubricants with water-based bio-compatible fluids has long been a desirable, if unrealised, ambition in many applications. This is particularly relevant in marine-based energy generation systems, where oil-based lubricants create a high risk of environmental pollution. The use of bio-lubricants has been explored in several previous studies, however no significant technological advances have been achieved. Most of the work has focused on traditional lubrication mechanisms, with bio-molecules being employed to form an adsorbed surface film which reduces friction. However, due to their inherent biological, thermal and/or oxidative instability, bio-molecules are unsuited to long-term industrial applications. The alternative approach is to use stable, bio-friendly molecules, designed to exploit the lubrication mechanisms found in nature. These mechanisms have evolved to be far more diverse than those found in traditional “mineral oil” tribology and are, as yet, poorly understood.

The effect of top of rail lubricant composition on adhesion has been investigated using a laboratory ball-on-disc tribometer. Rheological properties were analysed using viscosimeter and high pressure torsion device. As a base medium, a biodegradable ester oil with bentonite thickener was selected. Added particles for friction modification were aluminium oxide, zinc oxide, copper sulfide and solid lubricants molybdenum disulfide and graphite. The effect of these components in the base medium on adhesion was evaluated. It was found that the most dominant component was the solid particles for friction modification. Based on the results, top of rail lubricant substances were prepared and tested. The best performing substances provided the optimal level of adhesion. These substances also showed resilience to overdosing, which caused commercial products to provide very low adhesion conditions. The rheological investigation confirmed the very low adhesion is controlled by elastohydrodynamic regime while the stable values are a result of transition to boundary lubrication.

Electric vehicle motors in e-drivetrain are equipped with grease-lubricated bearings operating at both low and high speeds with frequent speed changes. The grease-bearing system must secure a long lifespan and low frictional torque to improve efficiency and sustainability. The present paper focuses on the influence of two types of thickener, lithium complex and polypropylene, on the grease lubrication performance under conditions typical for e-motors. The comparison of both thickeners is performed in terms of friction torque and energy consumption in eight long-duration experiments (337 hr). The results show that the polypropylene thickener provides 21.5% lower energy consumption compared to the lithium complex. Changes in grease rheology and degradation in the tests are analysed and correlated with the grease lubrication performance.

In the bearings’ segment of machine tools, there is a strong demand for high-performance steel solutions. The bearings may operate under severe conditions of contact pressures of up to 3 GPa; rotating at speed factors in excess of 3 million ndm. Such conditions pose a high risk of bearing seizure failure. Improving lubrication conditions is complex as the bearing operating temperature must be well controlled. Adhesive wear was found to occur in hybrid steel-ceramic contacts. Another relevant failure mode is micropitting. It is demonstrated that macroscopic hardness is insufficient to predict the resistance of steel microstructures to surface-initiated fatigue. In this regard, strain-hardening and the breadth of the range of hardness values of microstructure phases play an important role.

Nowadays, grease lubrication is frequently used in rolling element applications such as bearings or constant velocity joints. The advantage of grease is to supply lubrication to the application without leaking thanks to its consistency. Nevertheless, starvation can occur leading to damage such as scuffing.
In the present study, starvation is analyzed using the Starvation Degree parameter through tests with different operating conditions and different types of greases.

There is a high demand for environmentally friendly lubricants in order to support a transition to sustainable transport and manufacturing since conventional mineral oils derived from fossil sources are inherently harmful for the environment. Glycerol aqueous solutions have the potential to be used as environmentally friendly base fluids, due to their high solubility in water, and non-toxicity. In this investigation a micropitting test rig (MPR), was used to study the friction, wear and micropitting behaviour of Glycerol-based lubricants in a rolling/sliding contact. Micropitting and wear profiles were analysed through optical profilometry, and the morphology and evolution of micropits were studied trough scanning electron microscopy (SEM). The results showed that the steel-steel contact lubricated with a Glycerol-water-glycol lubricant reduced mild-wear, promoting micro-pitting as a main failure mode at low sliding levels compared to a commercial fully formulated gear oil. It was also shown that friction was significantly lower for the Glycerol-water and Glycerol-water-glycol lubricants which is mainly attributed to an effect of a low pressure-viscosity coefficient.