Motors

Greases
Grease is a combination of base oil (86-90%), additive(10%) and thickener(0 to
4%). The oil is trapped by the thickener. Oil does the lubricating and not the
thickener.

There are three main types of grease thickeners:

 Soap thickeners: Soap thickeners are made by reacting a metal salt with
a fatty acid. The resulting soap molecules form micelles, which are small
aggregates of molecules that have both hydrophilic (water-loving) and
hydrophobic (water-hating) ends. The micelles surround the oil droplets
in the grease, preventing them from coming into contact with each other
and forming a solid mass.
 Non-soap thickeners: Non-soap thickeners are made from a variety of
materials, including synthetic polymers, clays, and other materials. These
materials form a network of particles that traps the oil droplets in the
grease, preventing them from coming into contact with each other and
forming a solid mass.
 Combination thickeners: Combination thickeners are made by combining
two or more types of thickeners. This can be done to improve the
performance of the grease in specific applications. For example, a
combination of a soap thickener and a non-soap thickener can improve
the water resistance and shear stability of the grease.

The type of thickener used in a grease will depend on the specific application.
For example, soap thickeners are often used in greases that are used in high-
temperature environments, such as automotive wheel bearings. Non-soap
thickeners are often used in greases that are used in demanding applications,
such as metalworking.

The thickener is an important part of grease, and it plays a critical role in

providing the necessary lubrication, protection, and performance.

The typical viscosity of a base oil used in greases varies depending on the type of
grease and the application. For example, general-purpose greases typically have a
viscosity of 20-500 mm2/s at 40°C, while high-temperature greases may have a
viscosity of 500-1000 mm2/s at 40°C. The specific application will determine the
required viscosity of the base oil.

Here are some examples of typical viscosities of base oils used in greases:

 Mineral oil: Mineral oils typically have a viscosity of 20-500 mm2/s at 40°C.
 Synthetic oil: Synthetic oils typically have a higher viscosity than mineral oils.
For example, polyalphaolefin (PAO) oils typically have a viscosity of 500-1000
mm2/s at 40°C.
 Vegetable oil: Vegetable oils typically have a lower viscosity than mineral oils.
For example, soybean oil typically has a viscosity of 10-20 mm2/s at 40°C.

The viscosity of the base oil is important because it affects the performance of the
grease. A grease with a high viscosity will provide better protection against wear and
tear, but it will also be more difficult to pump. A grease with a low viscosity will be
easier to pump, but it may not provide as much protection against wear and tear.

When selecting a grease, it is important to consider the required viscosity for the
specific application. The required viscosity will depend on the type of equipment, the
operating conditions, and the specific requirements of the application.

Here are some additional details about some of the most common additives used in
greases:

 Anti-wear additives: Anti-wear additives are typically made from metal soaps,
such as zinc dithiophosphate (ZDDP). ZDDP is a very effective anti-wear
additive, and it is used in many greases. Other anti-wear additives include
molybdenum disulfide (MoS2) and graphite.
  Extreme pressure (EP) additives: EP additives are typically made from
chlorine or sulfur. Chlorinated paraffins and sulfurized lard oils are two
examples of EP additives. EP additives are used in high-pressure
applications, where they can provide additional protection against wear.
 Water-resistant additives: Water-resistant additives are typically made from
polymers or clays. These additives form a barrier that prevents water from
entering the grease. Water can contaminate the grease and reduce its
effectiveness.
 Corrosion inhibitors: Corrosion inhibitors are typically made from barium or
calcium sulfonates. These additives react with water to form a protective film
on metal surfaces. This film prevents rust and corrosion.
 Defoamers: Defoamers are typically made from silicone oils or polyglycols.
These additives break up foam that may form in the grease. Foam can reduce
the effectiveness of the grease.

Additives play an important role in the performance of greases. By selecting the right
additives, you can improve the performance of the grease and extend its service life.

There are a variety of grease testing methods that can be used to evaluate the
performance of greases. Some of the most common grease testing methods include:

 Penetration test: The penetration test is used to measure the consistency of

grease. The test is performed by inserting a standard cone into the grease
and measuring the depth of penetration. The higher the penetration value, the
softer the grease.
 Dropping point test: The dropping point test is used to measure the
temperature at which grease will flow. The test is performed by heating a
grease sample in a container and measuring the temperature at which the
grease drips from the container. The higher the dropping point value, the
higher the temperature at which the grease will flow.
 Water resistance test: The water resistance test is used to measure the ability
of grease to resist water contamination. The test is performed by placing a
grease sample in water and measuring the amount of water that is absorbed
by the grease. The lower the water absorption value, the better the grease's
water resistance.
 Rust prevention test: The rust prevention test is used to measure the ability of
grease to prevent rust and corrosion. The test is performed by placing a
grease sample on a metal surface and exposing the surface to a corrosive
environment. The test measures the amount of rust and corrosion that forms
on the metal surface. The lower the rust and corrosion values, the better the
grease's rust prevention properties.
 Load-bearing capacity test: The load-bearing capacity test is used to measure
the ability of grease to support a load. The test is performed by placing a
 grease sample between two metal surfaces and applying a load to the
surfaces. The test measures the amount of load that the grease can support
before it fails. The higher the load-bearing capacity value, the better the
grease's load-bearing properties.
 EP (extreme pressure) performance test: The EP (extreme pressure)
performance test is used to measure the ability of grease to protect against
wear and tear under high-pressure conditions. The test is performed by
placing a grease sample between two metal surfaces and applying a high
pressure to the surfaces. The test measures the amount of wear that occurs
on the metal surfaces. The lower the wear value, the better the grease's EP
performance.

The specific grease testing methods that are used will depend on the specific
application. For example, greases used in high-temperature applications may be
tested for their water resistance, rust prevention, and EP performance. Greases
used in low-temperature applications may be tested for their consistency, dropping
point, and load-bearing capacity.

Grease testing is an important part of ensuring the quality and performance of

greases. By testing greases, you can identify any potential problems with the grease
and take steps to correct them. Grease testing can also help you to select the right
grease for a specific application.