Hydraulic fluids are used in hydrostatic power systems to transmit power.

Water was the first fluid used for the transmission of fluid power. The main
advantages of water as hydraulic fluid are its availability, low cost, and fire
resistance. Water is of poor lubricity, has a narrow range of working temperature, and
has a high rust-promoting tendency.

The single most important material in a hydraulic system is the working fluid
itself. Hydraulic fluid characteristics have a crucial effect on equipment performance
and life. It is important to use a clean, high-quality fluid in order to achieve efficient
hydraulic system operation. Most modern hydraulic fluids are complex compounds
that have been carefully prepared to meet their demanding tasks. In addition to
having a base fluid, hydraulic fluids contain special additives to provide desired
characteristics.

Application for Hydraulic Fluids

The hydraulic fluids used in hydraulic installations must fulfil very varied tasks:

• pressure transfer,
• lubrication of the moving parts of devices,
• cooling, i.e. diversion of the heat produced by energy conversion (pressure
losses),
• cushioning of oscillations caused by pressure jerks,
• corrosion protection,
• scuff removal,
• signal transmission.

Basic Properties of Hydraulic Oils

Viscosity

Viscosity is the resistance to flow. It results from the cohesion and interaction
between molecules. When the viscosity is low, the fluid flows easily and is thin in
appearance. A fluid that flows with difficulty has a high viscosity and is thick in
appearance.

Too high a viscosity results in

1. High resistance to flow, which causes sluggish operation.

2. Increased power consumption due to frictional losses.
3. Increased pressure drop through valves and lines.
4. High temperatures caused by friction.
 If the viscosity is too low, the result is

1. Increased oil leakage past seals.

2. Excessive wear due to breakdown of the oil film between mating moving
parts. These moving parts may be internal components of a pump (such as
pistons reciprocating in cylinder bores of a piston pump) or a sliding spool
inside the body of a valve.

Viscosity Index (VI)

The viscosity index (VI) of oil is a number used in industry to indicate the effect
of temperature variation on the viscosity of the oil. A low VI signifies a relatively
large change of viscosity with temperature variation. A high-VI oil is one that has a
relatively stable viscosity, which does not change appreciably with temperature
change. The best oil is the one that maintains constant viscosity throughout
temperature changes.

Oil Density

The density is the mass per unit volume: ρ = m/V. The hydraulic oils are of low
compressibility and volumetric thermal expansion. Therefore, under ordinary
operating conditions, the oil density is practically constant.

Oil Compressibility

Liquids are of very low compressibility, while gases are highly compressible.
Therefore, liquids are usually assumed incompressible. But this assumption is applied
when the liquid compressibility has no significant effect on the performance of the
studied system. The liquid compressibility is defined as the ability of liquid to change
its volume when its pressure varies.

The hydraulic oil compressibility has a direct impact on the transient behavior
of the hydraulic system. Generally, the reduction of oil volume by 1% requires an
increase of its pressure by 10 to 20 MPa.

Thermal Expansion

The hydraulic liquids are subjected to volumetric thermal expansion. In the

case of oil trapped in a rigid vessel for a long period, the pressure may increase to
enormous values due to the rise in oil temperature. Considering a volume of oil
trapped in a hydraulic cylinder, the thermal expansion of the cylinder is negligible
with respect to that of the oil. Therefore, the oil volume remains constant, even
when its temperature increases, due to the combined effect of the oil compressibility
and its thermal expansion.
Lubrication and Anti-Wear Characteristics

The fluid must be capable of covering the contact surfaces of all moving parts
with a thin and continuous lubricating film. The lubricating film may be destroyed, as
a result of high loading forces, insufficient oil delivery, and low viscosity. This would
result in wear due to fretting.

Compatibility

The fluid must be fully compatible with other materials used in the hydraulic
system, such as those used for bearings, seals, paints, and so on. It should not react
chemically with any of these materials, nor change their physical properties.

Chemical Stability

Chemical stability is an important property of the hydraulic liquid. It is defined

as the ability of the liquid to resist oxidation and deterioration for long periods. All
liquids tend to undergo unfavourable changes under severe operating conditions.
Some metals, such as zinc, lead, brass, and copper, have undesirable chemical
reactions with certain liquids. These reactions result in the formation of sludge,
gums, carbon, or other deposits.

Oxidation Stability

The oxidation stability is the ability of the fluid to resist chemical degradation
by reaction with atmospheric oxygen. The degradation of hydraulic fluids by oxidation
can result in significant viscosity increases, development of corrosive organic acids,
and lacquering of critical surfaces by resinous oxidation products.

Foaming

All fluids contain dissolved air. The amount of dissolved air depends upon the
temperature and pressure. Typically, mineral-based oil can contain up to 10% by
volume of dissolved air. As the temperature of the fluid increases or the pressure
decreases, the dissolved air is liberated. The liberated air exists in the fluid as
discrete bubbles. When the fluid containing the entrained air returns to the reservoir,
the air rises to the surface and causes foam. If the foam builds up, it can cause severe
problems in the hydraulic system. Therefore, most hydraulic fluids contain foam-
depressant additives that cause the rapid breakdown of the foam.

Cleanliness

Fluid cleanliness is of primary importance because the contaminants can cause

component malfunction, prevent proper valve seating, cause wear in components,
and may increase the response time of servo valves.
Acidity

An ideal hydraulic liquid should be free from acids that cause corrosion of the
metals in the system. The degree of acidity of a liquid, when new, may be
satisfactory, but after use, the liquid may tend to become corrosive as it begins to
deteriorate.

Toxicity

Toxicity is defined as the quality, state, or degree of being toxic or poisonous.

Some liquids contain chemicals that are a serious toxic hazard. These toxic or
poisonous chemicals may enter the body through inhalation, by absorption through
the skin, or through the eyes or the mouth. The result is sickness and, in some cases,
death.

Classification of Hydraulic Fluids

Mineral-based oils

Mineral-based oils are the most widely used hydraulic fluids. They are of good
lubricity, noncorrosive and compatible with most sealing materials. Mineral oils are
chemically stable for reasonable operating temperatures. At higher temperatures,
however, they suffer a chemical breakdown. Fire risk excludes the use of mineral oils
in hazardous areas such as injection and plastic molding machines.

Fire-Resistant Fluids

Oil-in-Water Emulsion

This hydraulic fluid consists of tiny droplets of oil dispersed in a continuous

water phase. It is extremely fire-resistant, is highly incompressible, and has good
cooling properties. Its main disadvantages are poor lubricity and low viscosity.

Water-in-Oil Emulsion

The water-in-oil emulsions are the most popular fire-resistant fluids. They have
a continuous oil phase in which tiny droplets of water are dispersed. The usual
dilution is 60% oil + 40% water. At higher temperatures, water content is affected
owing to evaporation, which decreases the emulsion's fire-resistance properties. When
the system has been idle for long periods, there is a tendency for the oil and water to
separate. However, during running, the pump will re-emulsify the fluid.
 Water-Glycol Fluids

These fluids were developed primarily for use in aircraft because of their low
flammability characteristics. Their application is limited since they cannot be used at
high temperatures. Their lubricating ability is inferior to that of mineral oils.

Synthetic Oils

Synthetic oils have remarkably good fire-resistance properties. They are used in
industries such as plastic molding and die-casting, where unusually great fire risks
occur. Their lubricating ability is similar to that of mineral oil.

Additives

The largest class of hydraulic fluids consists of refined hydrocarbon base oils
(petroleum oils) and suitable additives to improve the base properties. The main
types of additives used in hydraulic fluids are the following.
• Oxidation inhibitors improve the ability of liquid to withstand chemical
reaction with oxygen/air and avoid subsequent degradation. They are of prime
importance when operating at elevated temperatures.
• Corrosion inhibitors form molecular layers that are bound to the surface by
electrostatic forces and form an effective barrier against penetration by
oxygen and water, which is necessary for rust-forming electrochemical
reactions.
• Antifoaming agents, which form small heterogeneous areas within the bubble
walls of surface foam. Due to their low surface tension, these small areas are
weak spots and result in bubble bursting.
• Anti-wear additives of high thermal stability.
• Viscosity index improvers
• Pour point depressants
• Friction modifiers are necessary under certain conditions to ensure smooth
operation, free from juddering (stick/slip).
• Detergents are substances providing a cleaning action with respect to the
surface deposits.
•
A hydraulic fluid has the following four primary functions:

1. Transmit power
2. Lubricate moving parts
3. Seal clearances between mating parts
4. Dissipate heat
 In addition a hydraulic fluid must be inexpensive and readily available. To
accomplish properly the four primary functions and be practical from a safety and
cost point of view, a hydraulic fluid should have the following properties:

• Satisfactory flow properties throughout the entire range of operating

temperatures.
• A high viscosity index that ensures moderate viscosity variation in relation to
the temperature fluctuations.
• Good lubricating properties are a prerequisite to reduce the wear and
increase the service life of the system.
• Low vapor pressure to avoid cavitation.
• Compatibility with system materials since the fluid should not react chemically
with any of the used materials or deteriorate their physical properties.
• Chemical stability is necessary to increase the service life of liquid and avoid
performance deterioration.
• Corrosion protection by adding effective corrosion inhibitors.
• Rapid de-aeration and air separation.
• Good thermal conductivity is required to rapidly dissipate the heat generated
due to friction between elements and due to hydraulic losses.
• Fire resistance is essential in some applications.
• Electrically insulating properties can be significant in a number of modern
designs.
• Environmental acceptability.