Basic of Lubricants Lubrication

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

Hydrodynamic lubrication Also called complete or full flow Occurs when two surfaces are completed separated by a fluid film
Methods of lubrication
Two main methods
cont..
Hydrodynamic lubrication Boundary lubrication

Boundary lubrication Occurs when Hydrodynamic lubrication fails. By adsorption or chemical reaction
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
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
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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

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)
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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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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)
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
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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
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
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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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
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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
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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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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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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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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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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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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
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
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
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
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
--
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
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.

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

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
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

Hussam Adeni
110 165 242 352 506 748 1100 1650
315 465
700 1000 1500 2150 3150 4650 7000
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

Thank you
Hussam Adeni

Basic of Lubricants Lubrication

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Basic of Lubricants Lubrication

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The Basics of Lubricants and lubrication

Hydrodynamic lubrication Boundary lubrication

Hydrodynamic lubrication Boundary lubrication

Types of Lubricant - Physical

Types of Lubricant - Physical

Typical lubricants - Application

Typical lubricants - Application

Heat Treatment Oils Quenching Oils Tempering Oils Refrigeration Oils

Ink process Oils

Protection prevent wear

Lubricate reduce friction

Reduces ill effect of friction

heating, lead to wear, distortion and failure.

Removes external contaminants dust,

Very important to increase life of

component and equipment

Kinematic Viscosity Recommendations

Measured in Mg KOH/gm of oil

Lab Tests - for lubricants

Kinematic viscosity Viscosity index Pour Point Flash Point

ASTM ASTM ASTM ASTM ASTM ASTM

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

What are additives Lubricant additives

What are additives What they do in Engine Oils

Extend the range of lubricant applicability Extend lubricant life

Surface Protective additives

Surface Protective additives - Automotive Lubricants

Surface Protective additives - Automotive Lubricants

Surface Protective additives - Automotive Lubricants

Surface Protective additives - Automotive Lubricants

Surface Protective additives - Automotive Lubricants

Performance additives - Automotive Lubricants

Performance additives - Automotive Lubricants

Performance additives - Automotive Lubricants

Performance additives - Automotive Lubricants

Performance additives - Automotive Lubricants

Performance additives - Automotive Lubricants

Lubricant - Nomenclature and Specifications

SAE Eng ine Oils

SAE Gear Oils

5000 1000 800

Viscosity Grade Classification Systems 400

AGMA Industrial Gear Oils

500 500 400 400 300

SAE Engine Oils

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

SAE Gear Oils

Major specifying organizations

SAE viscosity grades for engine oils

SAE viscosity grades for engine oils

SAE viscosity grades for Mono grades - Engine Oils

SAE viscosity grades for Multi grades - Engine Oils

SAE Crankcase Oil - Viscosity classification Winter Service

9500@ -15 13000@ -10

-40 -35 -30 -25 -20 -15

3.8 3.8 4.1 5.6 5.6 9.3

SAE Crankcase Oil - Viscosity classification Summer Service

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

API Automotive Gasoline Engine Service Categories SA, SB,

Engine Test Requirements

Sequence IIA Sequence IIA Sequence V

CRC L-38 Sequence IV