Dr.

Mattias Forslund, Materials technology for Electrification applications

Evolution of Lubricants for

Electrified Transmissions at Scania
E-motor failure case study
 Mattias Forslund

• M.Sc. in Material Chemistry from Uppsala University,

Sweden
• Ph.D. in Chemistry/Corrosion Science from Royal
Institute of Technology (KTH), Sweden
• Inspection Engineer at Nynas AB.
• Development Engineer of Materials for eMobility at
Scania CV AB, Sweden

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Scania
Trucks Buses and coaches

Choosing from customised

heavy trucks, buses,
engines and services,
our customers can build
a variety of cost-efficient, Engines Services
low-carbon solutions.

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
examples of electrified Scania
vehicles
BEV Truck PHEV Truck

BEV Bus

eHighway
2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
PHEV Bus
 PHEV Truck

Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications

PHEV drive train

Electric motor

Gearbox

Diesel Engine

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Synchronous Permanent magnet Motor

Stator

Hairpins

Rotor
Permanent
magnets
2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
 Failure position
Spray cooling
from top
Stator

Oil level

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
 Failure position
Spray cooling
from top
Stator

Failures typically
occur at 1 o’clock
position on the
stator.
I.E. above the oil
level!

Oil level

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
field quality issues HEV
Short circuit after 6000 h in operation in bus operation in
europe
Likely root cause top up of 10-15% of axle fluid

eMachine stator after failure

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Failure mode
• Sulphur-induced corrosion of the copper wire causes a buildup of
conductive copper sulphide layer.
• The copper sulphide can bridge between different phases => short circuit
• We need a method to test corrosion.

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Qualitative analysis

ASTM D130

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Qualitative analysis

Test setup hair pin corrosion test

Closed Open

Closed

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Qualitative analysis

125°C @ 168h Test setup: Closed

Axle oil 1st gen MTF 2nd gen ATF 3rd gen e-Fluid
Vapour phase

NEW
polished
125 °C

TEX multigear 125 °C BASF 125 °C 168h Air (CP)

A295 125 °C 168h Air OS411358M 125 °C 168h Air
168h Air (CP) (CP) (CP)
Oil phase

TEX multigear 125 °C BASF 125 °C 168h Oil (CP)

168h Oil (CP) A295 125 °C 168h Oil (CP) OS411358M 125 °C 168h Oil
(CP)

A295 150 °C 168h

Air (CP)
Quantitative analysis

Wire corrosion test

• Copper wire (64 µm diameter) is exposed to oil.
The electrical resistance is monitored during
the test and thus the corrosion rate can be
determined
• The entire setup with beaker is immersed in
oilbath and heated to ~140 °C in the oil phase
and ~80 °C in the
vapour phase.
• The duration of the test was 96 hours (4 days).

Copper wire

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Quantitative analysis

Relative corrosion rate oil phase

• Copper corrosion is affected by the type of oil used!
Oil phase

-80%

-10%
-90%

axle oil 1st gen MTF 2nd gen ATF 3rd gen eFluid

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Quantitative analysis

Importance of the vapour phase

• Corrosion rate in vapour phase is much higher than in oil phase!
RELATIVE CORROSION RATE
Vapour phase Oil phase

Corrosion rate in vapour

phase is ~10 times higher!

axle oil 1st gen MTF 2nd gen ATF

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Concluding remarks

Axle
oils

MTF
Scuffing resistance

ATF

eMotor
fluid
Separate oil systems between
gearbox and eMotor

Compatibility to electric machine

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Concluding remarks

Axle
oils Higher temperatures
Higher power density

Dedicated
MTF
Scuffing resistance
eFluid

ATF

eMotor
fluid
Separate oil systems between
gearbox and eMotor

Compatibility to electric machine

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Concluding remarks
• EP-type lubricants are corrosive towards copper, especially in the vapour
phase

• Dedicated fluids which combines the gear protection of MTF and

excellent copper corrosion protection is desireable but probably need
new types of chemistries to be developed
− I.e new type of scuffing protection and/or better corrosion inhibitors

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications
Questions
• Visit our website:
www.scania.com

• Contact me:
− mattias.forslund@scania.com

2021-10-27 Scania Mattias Forslund, Ph.D., Materials technology for Electrification applications