LLA I Day 2

Fundamentals of Lubrication
Wear Surface Finish/Asperities - Explain

 Friction
 Lubrication – Establishing a Film
 Film Properties are Dependent on Oil Viscosity.
 Viscosity is the Measurement of the Flow Rate of a Liquid at a Specific Temperature
 Viscosity

Viscosity

Definition: Internal resistance to flow and shear. It is the measure of the “flow-ability” of an oil at pre-
set temperatures

This Property is Influenced by:

 Temperature
 Contaminants
 Moisture
 Solids
 Chemical Changes

Viscosity

Viscosity Examples

Measurement of Kinematic Viscosity

Kinematic Viscosity (cSt)

Used for Finished Lubricants and Used Oil Analysis – measured in seconds2/cc

1. Oil is drawn into tube by suction.

2. The tube is submerged in constant temperature bath.

3. Temperature is kept at 40C (industrial oils) or 100C (engines).

4. The flow of the oil to flow from start to stop mark.

5. Various constants and the time measured determine the viscosity.

Measurement of Absolute Viscosity

Function of the Absolute Viscometer

The Spindle turns in oil reservoir

Torque (resistance) is measured

Viscosity is reported in Centi-Poise (cPs)

Multiplying cSt by the Specific Gravity provides cPs

Failure Modes in Lubricated Systems

Wear

 Abrasive Wear
 Adhesive Wear
 Fatigue Wear
 Corrosive Wear
 Cavitation Wear
 Erosive Wear

Contaminants

 Particulate
 Water
 Fuel
 Coolant

Oil Condition & Properties

 Viscosity Change
 Acid Generation
 Oxidation
 Sulfation
 Nitration

Wear

6 Wear Mechanisms

 Abrasive Wear
 2 Types of Abrasive Wear
 Abrasive Wear Example
 Adhesive Wear
 Adhesive Wear Examples
 Fatigue Wear
 Fatigue Wear Examples
 Corrosive Wear
 Corrosive Wear Examples
 Examples of Corrosive Pitting
 Cavitation
  Restricted inlet flow to pump causes fluid voids that implode, causing shocks 2,000,000 lbs/sq in
that break away critical surface material.

Cavitation Erosion

 Cavitation
 Cavitation Wear Examples
 Pseudo Cavitation
 Pseudo Cavitation is caused by air entrainment
 Erosive Wear
 Erosive Wear Examples
 Contaminantes
 Contamination

Particulate

 Internal
 External
 Born

Water

 Leaks
 Humidity
 Process

Process

 Fuel
 Coolant
 Product

Oil Condition & Properties

Oil Condition & Properties

Viscosity Change

 Increase
 Decrease

Acid Generation

 Heat
 Water
 Catalysts

Polymerization

Oxidation
Nitration

Sulfation

Function of a Lubricant

 Reduces Friction (Wear & Heat)

 Absorbs or Dampen Shock
 Carries Away Heat
 Cleans Surfaces / Suspends Particulate
 Prevents Rust & Corrosion
 Seals Out Dirt / Contaminants
 Acts as a Flushing Agent
 Transfer Power
 Act as a Conduit of Information

Important Lubricating Oil Properties

 Viscosity
 Viscosity Index
 Oxidation Stability
 Water Separation
 Wear Protection
 Anti-Foaming
 Pour Point
 Flash Point / Fire Point
 Aniline Point
 Acid Neutralization
 Dielectric Strength

Lubricant Properties

Viscosity

The single most important property of a lubricating oil. The viscosity is determined in accordance with
the mechanical requirements of the system.

Viscosity Index

The viscosity index is a measure of how much variation will occur in the viscosity of a lubricant over a
wide temperature range.

Oxidation Resistance

Chemical reaction of oil and oxygen to form organic acids, varnish and sludge catalyzed by heat, water
and metals; oxidation rate doubles every 10°C or 18°F rise in temperature.

Lubricant Properties

Anti-wear
A measure of the oils ability to prevent against surface to surface contact.

Extreme Pressure Protection

The ability of the oil to prevent surface seizure due to extreme loads and friction

Friction Modifier

Surface modification to either increase the coefficient of friction or reduce it depending upon the system
requirement.

Lubricant Properties

Water Separation

Also known as demulsibility, the ability of an oil to separate from water

Flash Point/ Fire Point

Temperature at which oil vapors produce a momentary flash if a flame is applied is flash point; and, if it
burns for five seconds, this is the fire point.

Pour Point

Lowest temperature at which an oil will flow under controlled conditions; presence of wax raises pour
point.

Lubricant Properties

Acid Neutralization

Acidity or alkalinity of oil is called acid number or base number. Acidity (Acid #) increase caused by oil
oxidation.

Alkalinity (base #) occurs from detergents in engine oils to neutralize acids.

Anti-foaming

Combination of air and oil to form a froth; mixture which interferes with oil circulation and provides
inadequate film.

Aniline Point

An empirical measure of the solvent power of a hydrocarbon.

The lower the aniline point, thegreater the solvency.

Oils with a low aniline point havegreater tendency to attack seals.

Lubricant Properties

Dielectric Strength

The ability to electrically insulate a component by inhibiting the flow of electric current.
Rust & Corrosion Protection

The ability to protect the metal surface from oxidizing agents that would lead to metal corrosion.

Detergency & Dispersency

Detergency keeps metal surfaces clean.

Dispercency keeps particles in solution.

Oil Viscosity Classifications

Absolute Viscosity (Dynamic)

Kinematic Viscosity

Saybolt Universal Viscosity

ISO

AGMA

SAE

Measurement of Kinematic Viscosity

Kinematic Viscosity (cSt)

Used for Finished Lubricants and Used Oil Analysis – measured in seconds2/cc

1. Oil is drawn into tube by suction.

2. The tube is submerged in constant temperature bath.

3. Temperature is kept at 40C (industrial oils) or 100C (engines).

4. The flow of the oil to flow from start to stop mark.

5. Various constants and the time measured determine the viscosity.

Kinematic Viscosity

Measure of fluid’s resistance to flow under gravity and related to fluid’s density

Measured in Centistokes cSt.

ISO viscosity classifications are based on Kinematic viscosity.

This viscosity is generally measured at 400C and at 1000C or 2120F.

Measurement of Absolute Viscosity

Function of the Absolute Viscometer

The Spindle turns in oil reservoir

Torque (resistance) is measured

Viscosity is reported in Centi-Poise (cPs)

Multiplying cSt by the Specific Gravity provides cPs

SAE Engine Oil Viscosity Origins

“In 1911 the SAE published the first version of their standard (SAE J300) for motor oil viscosity. The SAE
wanted a system that reflected the suitability of an oil for use as an engine lubricant and was easy for
the consumer to understand. Their initial specification defined five different numbered grades for motor
oil (10, 20, 30, 40, and 50). The grades were based on flow rates measured at 210° F (100° C) as shown in
the table.

Saybolt Universal Seconds Viscosity [SUS]

Viscosity measured in time (seconds) required for 60 ml of oil to flow through an orifice of the Saybolt
viscometer at a given temperature (100F or 210F).

SAE Engine Oil Viscosity Grade – Cold Crank Simulator

SAE Engine Oil Viscosity – Cold Pump Simulator

SAE Engine Oil Viscosity – High Temperature High Shear (HTHS)

HTHS Viscosity measured at 150C under constant shearing / high speed

Mimics high temperature and high forces in engines

Oil Film between Rotor and Stator – resistance to flow creates addition Torque to turn spindle

Viscosity Measurement Comparisons

Kinematic Viscosity

Measure of fluid’s resistance to flow under gravity

Derived from the time taken for a lubricant to travel through a capillary tube.

Unit of measure – Stoke (St) Named after George Gabriel Stokes = 1 cm2 / second

Typically reported as centistoke (cSt) = 1 mm2 / second

Absolute Viscosity

Measure of a fluid’s resistance to flow under an applied force

Derived from the force required to turn a spindle submerged in a lubricant.

Unit of measure – Poise (P) Named after Jean Léonard Marie Poiseuille = dyne • s/cm2

Typically reported as centipoise (cP) Absolute Viscosity = Kinematic Viscosity x Density

Saybolt Universal Seconds

Measure of fluid’s resistance to flow under gravity

Derived from the time for 60 ml of fluid to flow through a calibrated orifice

Unit of measure – Saybolt Universal Second (SUS or SSU) Named after G.M. Saybolt

Quick Conversion

Kinematic Viscosity = Saybolt Viscosity ÷ 5

SAE Engine Oil Viscosity Classification

Low Temperature Cranking

Low Temperature Pumping

Min / Max Kinematic

High Temp. High Shear

SAE Gear Oil Classification – J306

AGMA Viscosity

Viscosity Comparison

Kinematic Viscosity 40C, 100C

Saybolt Viscosity 100F, 210F

ISO

SAE

AGMA

Viscosity Index Calculation

For the unknown oil: Y = Kinematic viscosity @ 100 C and U = Kinematic viscosity @ 40 C.

You need two reference oils. One with a VI of 100 and one with a VI of 0. Both must have the same
viscosity as the unknown oil @ 100 C.

H = Kinematic viscosity @ 40 C of the VI=100 oil

L = Kinematic viscosity @ 40C of the VI=0 oil

The VI of the unknown oil is then:

VI = 100(L-U)/(L-H).

Viscosity Index & Temperature

The blue product thins less as the temperature rises and thickens less as the temperature falls because
of its higher VI value. With a Vis./Temp chart one can predict the operating temperature of any
lubricant.

High Viscosity Index

Benefits: Better equipment protection at start-up and at high temperatures.

Viscosity Relationships

AGMA Industrial Enclosed Gear Oil Classification

AGMA Industrial Gear Oil Viscosity Recommendation

AGMA Industrial Gear Oil Viscosity Recommendation for a Final Reduction Gear

AGMA Industrial Gear Oil Viscosity Recommendation for Continuous & Intermittent Applications

SAE J300 Viscosity Classifications

Low Temp (to -40C)

Operating Temp (100C & 150C)

SAE J306 Viscosity Classifications

Viscosity Comparison

High Viscosity Index

Benefits: Better equipment protection at start-up and at high temperatures.

API Base Oil Classifications

Synthetic Oils

Synthetic Lubricant Advantages

Fire Resistance

Oxidation Stability

Thermal Stability

Higher Viscosity Index

Better Lubricity

HigherFlashpoint

Lower Pour Point

Good Demulsibility & Low Foaming

Natural Detergency

Wide Operating Temps

Synthetic Lubricant Disadvantages

High Cost

High Disposal Cost

Toxicity

Hydrolytic Stability

Seal Compatibility

Mix-Ability

Synthetics Can Have a Low Coefficient of Friction

Synthetics Can Have a High Film Strength

Synthetic Oil Temperature Limits

MLA II

PHYSICAL & CHEMICAL TESTS

FLUID PROPERTY AND CONTAMINANTS

Color ASTM D1500

Test is conducted using a Colorimeter to visually inspect the samples and determine the color

The fluid sample is compared to color standards according to the ASTM Color Scale

The results are reported from 0.5 – 8.0

The higher the number, the darker the fluid

Highly oxidized turbine oils will become dark when compared to new oil

Also, lube mixing and other contamination may cause a color change

Colorimeter

ASTM D1500 – Rating 0 - 8

Copper Strip Corrosion - ASTM D130

This test is designed to assess the relative degree of corrosivity of the petroleum product.

In-service oil contamination/degradation may stimulate sulfur compounds into becoming actively
corrosive.

Copper Corrosion

A polished copper strip is immersed in a specific volume of sample, in a pressured vessel, and heated @
50ºC for 3 hours.

At the end of the heating period, the strip is removed, washed, and the color and tarnish level is
assessed against the ASTM Copper Strip Corrosion Standard.

The results are determined and the tarnish and color of the strip are expressed.

Copper Test Results

Slight tarnish 1 a,b

Moderate tarnish 2 a,b,c,d,e

Dark tarnish 3 a,b

Corrosion 4 a,b,c

Copper Strip Corrosion

Rust Preventing - ASTM D665

In many instances water can become mixed with the oil, resulting in rust of ferrous metal surfaces.

This test is designed to determine how well inhibited mineral oils aid in preventing this type of rusting
from occurring.

The test results are Pass or Fail.

Rust

A mixture of 300 mls of oil are stirred with 30 mls of distilled water (Procedure A) or synthetic sea water
(Procedure B) at a temperature of 60ºC with a polished cylindrical steel test rod completely immersed
therein.

At the end of 4 hours, the test rod is removed, cleaned off, and visually observed for any signs of rust.

If rust is observed, the test is a Failure. If no rust is observed, the test has been Passed.

Copper Strip Corrosion

Foaming Tendency - ASTM D892

The tendency of oils to foam can become a serious problem in some systems.

The results of excessive foaming may lead to inadequate lubrication, cavitation, and overflow loss of oil,
all of which may cause mechanical failure.

This is a 3-part test: Sequence I, Sequence II and Sequence III

Foam Test

A 190ml of oil sample is preheated to 120ºF, allowed to cool down to 75ºF, then poured into a
graduated cylinder and immersed into a constant temperature bath at 75ºF

With a diffuser, air bubbles are blown through the oil sample at a constant rate for 5 minutes.

After 5 minutes, the air is turned off, and the amount of foam is immediately recorded in mls.

The oil is then allowed 10 minutes to settle and the amount of foam is again measured.

This is Sequence I.

Foam Test

Sequence II and Sequence III are identical procedures to Sequence I, except the bath temperature is
changed.

Seq. II – 200ºF
Seq. III - 75ºF again

Report example “Seq. I 20/0” indicating 20 mls of foam after 5 minutes of air, and 0 mls of foam after
10 minutes of settling.

Copper Strip Corrosion

Varnish Potential

Varnish

May be defined as a thin, hard, lustrous, oil insoluble deposit, composed primarily of organic residue,
and most readily definable by color intensity. It is not easily removed by wiping and is resistant to
saturated solvents. Its color may vary but usually appears in gray, brown and amber hues

May Be Soft - Sludge

May Be Hard - Lacquer

Anything In Between

Varnish

The most numerous incidents involve systems that utilize the turbine oil as a hydraulic medium for
activating servo-valves

The Problem

The Problem

Modern turbine oils, which do last longer, start to degrade rapidly and suddenly

Because their routine oil analysis reports are normal, this may lull the user into a false sense of security

Blotter Test- ASTM D4740 (M)

Dark inner ring circle from a single oil drop on No.2 Whatman chromatographic paper.

Rating 1 through 5 using the ASTM D4740 rating chart.

Ultracentrifuge

Membrane Patch Colorimetry, Part 1

ASTM Work Item WK13070

We utilize Automatic Colorimetry which quantifies patch color utilizing CIE_dE, delta energy (ΔE) units,
to report the mathematically precise coloration of the resins and other varnish debris trapped on the
filter patch.

Membrane Patch Colorimetry, Part 1

ASTM Work Item WK13070

Color ranges are defined by the color on the patch. The more color, or higher the CIE delta energy
values, the higher the varnish potential. Ranges are
Normal = < 15 CIE_dE

Monitor = 15 - 30 CIE_dE

Abnormal = 30 – 40 CIE_dE

Critical = > 40 CIE_dE

Membrane Patch Colorimetry, Part 2

Varnish Potential Pentane Insolubles

Weight of the membrane patch is measured to detect the high molecular weight insolubles that form
varnish

Ruler

ASTM D6971/D6810

Remaining Useful Life Evaluation Routine

Quantifies the hindered phenol and aromatic amine additive levels in turbine oils by linear sweep
voltammetry

The antioxidant additive levels of the in-service fluid is compared to a reference sample of the new
(unused) product

Ruler

Data is obtained by measuring the current passing through the electrolytic cell as a function of the
potential applied

The test results are based upon current, voltage, and time relationships at the cell electrodes

Ruler Readout

Ruler Readout

Varnish Potential Report

After correlating all of the test results, the data analyst communicates the Varnish Potential in a report
to the customer

Levels reported are:

Low

Moderate

Elevated

High

Particle Analysis
Types Of Particles

Normal rubbing wear

Severe rubbing wear

Cutting wear

Chunks

Laminar wear

Spheres

Dark metallo-oxides

Red oxides

Corrosive wear

Nonferrous metals

Nonmetallic particles

Friction polymers

Fibers

Distinction Of Particles

Distinction Of Particles

Roller bearings

Fatigue spalls
> 15µm

Gears

Abnormal wear
> 40µm

Spectrometer limit

Less than 5-10µm

Distinction Of Particles

How Big Is A Micron?

Relative size of particles…

ISO Particle Count

ISO 4406:1999 (ISO 11171)

Particle count and ISO Cleanliness Code

Distinction of Particles

PQ is a sensitive Magnetometer that measures the mass of ferrous wear debris and displays this as a PQ
Index

The PQ Index is a unitless quantitative number that can be trended with good linearity over a wide range
of ferrous debris content and particle size

PQI is most effective when used along with the iron concentration in ppm from the spectrometer

PQ Index - PQI

Use in conjunction with spectroscopic wear metals analysis

When iron is HIGH and PQ is LOW, indicates small particles

When iron and PQ are approximately the SAME, indicates small particles

When PQ is HIGH and iron is LOW, indicates large particles and possible significant wear

PQ Index - PQI

Measures the “Total Ferrous Content” of the oil irrespective of particle size

Ferrography

Test Methods:

1. Direct Reading Ferrography

2. Analytical Ferrography

Wear Progression

Direct Reading Ferrography

Direct Reading Ferrography

Direct Reading Ferrography

DR Ferrography

Use of electronic sensors and magnets to measure concentration of ferromagnetic particles.

Ability to measure large particles, up to 200 microns, which is a good indicator of impending severe
machine damage.

Results may be reported as wear particle concentration (WPC) and reported as small (S) <5 microns and
large (L) >5 microns.

Evaluation of large to small ratio indicates wear severity

Analtyical Ferrography
Microscopic Particle Examination(mpe)

Distinction Of Particles

Sliding wear may be distinguished from rolling contact fatigue wear in that sliding wear particles have
surface striations and straight edges, whereas rolling contact wear particles have smooth surfaces and
jagged edges

Oxidative wear modes

Dark metallo-oxides are typically produced in highly loaded, poorly lubricated systems

Red oxides (rust) are present due to water contamination

Corrosive wear is generated by acid attack at wearing contacts

The ability to distinguish between wear modes will allow choice of the proper corrective action.

Analytical Ferrography

Analytical Ferrography

Slidemaker

Ferrogram

Bi-Chromatic Microscope

AF Techniques

Initially, the ferrographer quantifies the percentage of area under examination covered by particles

Using bichromatic illumination (red reflected light and green transmitted light) and a 10x objective, one
can quickly scan the ferrogram for any large (>15 µm) metallic particles which appear highly reflective

Using white light, the details of the particles of interest may be examined at higher magnification
(usually 40x, 80x or 100x)

A calibrated reticle in the ocular lens determines length or size of the particle

Thickness is determined by measuring the stage travel between focus on the top of the particle and
focus on the plane of the surface of the ferrogram

Wear Distinction

Spherical Particles, Unique To Fatigue, Pre-Spall

Cutting Wear - Abrasives

Red Oxides - Rust

Corrosive Wear

Distinction Of Particles
Nonferrous metals are easily recognized by their paramagnetic deposition patterns

Copper alloys are a distinctive yellow/orange

White nonferrous metals can be distinguished by heat treating the ferrogram and by wet chemical tests
done on the ferrogram

Molybdenum disulfide can easily be identified by its dull gray appearance and the presence of multiple
cleavage planes

Nonferrous - Copper

Nonferrous - Aluminum

Distinction Of Particles

Nonmetallic particles (dirt, fibers, seal material, paint ships, plastics & polymers, carbon, coal dust, etc.)
may be recognized using a variety of techniques

Polarized filters

Colored filters

Heat treating the ferrogram

Friction polymers are easily recognizable by their flatness and embedded wear particles in the polymer

There are sometimes amorphous particles as well

Dirt

Cellulose Fiber - Glass Fiber

Distinction Of Particles

Heat Treatment

Distinction Of Particles
Oil Specification

Testing

Specification Test Purposes

Aid in the development of new lubricants and additive systems

Set minimum specification requirements by OEM’s

Assist the end user in the selection of a lubricant for a particular application

Use as a general indicator for a lubricant’s actual performance in the field

Typical Turbine Specification Tests

Typical Hydraulic Oil Specification Tests

Typical Gear Oil Oil Specification Tests

Lubricating Oil Specification

Tests

Kinematic Viscosity (ASTM D-445)

The time is recorded in seconds for a fixed volume of fluid to flow through a calibrated capillary tube at
both 40ºC and 100ºC

The viscometer selected should give a flow time > 200 seconds

Viscometers are calibrated using standard oils having viscosities established with reference to water

Units are expressed as centistokes (cSt)

The flow of liquid in seconds x the viscometer calibration expressed as centistokes per second gives the
viscosity in cSt of the fluid

Viscosity also expressed as mm2 /sec

ISO Viscosity Classification System

Color ASTM D-1500

Test is conducted using a Colorimeter to visually inspect the samples and determine the Color

The fluid sample is compared to Color standards according to the ASTM Color Scale
The results are reported from 0.5 – 8.0

The higher the number, the darker the fluid

Highly oxidized turbine oils will become dark when compared to new oil

Also, lube mixing and other contamination may

cause a color change

Color Scales

Viscosity INDEX

Viscosity index is a number that measures the rate of change in viscosity of an oil as it is heated

The higher the viscosity index number the less the oil thins upon heating

Viscosity index is calculated as follows:

Flash Point (ASTM D-92)

Cleveland Open Cup Method

Test Procedure

Cup filled with oil sample

Oil heated at rate of 9 to 11ºF per minute

At every 5ºF rise in temperature a small flame passed over oil surface

When a flash occurs the temperature is recorded as the flash point

Heating is continued and a flame is applied every 5ºF rise in temperature

When oil ignites and burns for at least 5 seconds, the fire point is recorded

Flash point useful for safety and also indicates temperature at which evaporation losses occur

Cloud And Pour Points (ASTM D-2500 & D-97)

Cloud point is the temperature at which wax begins to crystallize from an oil sample which is indicated
by a haziness in the sample

Cloud point useful as indicator of temperature where filter plugging might occur

Pour point determined by cooling sample in 5º increments until no surface movement is observed for
five seconds when test tube is in horizontal position and the pour point is the last temperature at which
movement occurred

Pour point good indicator of low temperature behavior of oils

Select an oil about 20ºF above the pour point not to encounter pumping problems at low temperatures

Neutralization Number (ASTM D-974)

Base number normally determined for engine oils to indicate reserve alkalinity available to neutralize
combustion acidic components

The increase in acidity of a used oil is used as an indicator of oxidation

Test used to determine the acidic or basic components in an oil sample

Acid number determined by neutralizing one gram sample with KOH

Basic number determined by neutralizing one gram sample with perchloric acid

Results expressed for both as milligram equivalents of KOH

Neutralization Number (ASTM D-974)

Each new oil has an acid number which indicates acidity normally caused by additives

Turbine oils ~ 0.05 – 0.1

Hydraulic oils ~ 0.40

Gear oils ~ 0.80

Rust Prevention Test (ASTM D-665 A/B)

Test predicts the ability of an oil to prevent rusting of steel parts

Test is an excellent field predictor of rust inhibition properties of oil

Test Procedure

Insert 300 ml sample in beaker

Stir and heat to 140ºF

Insert polished steel rod

After 30 minutes add 30 mls of distilled water or sea water

Normally results reported individually for distilled and sea water

665 A is distilled water and 665 B is sea water

Rust Prevention Test (ASTM D-665 A/B)

Continue test for 4-24 hours

Observe condition of rod

No rusting is a pass

Light six spots or less

Moderate less than 5% of surface

Severe more than 5% of surface

Copper Strip Corrosion Test (ASTM D130)

Test measures the corrosivity of an oil to copper or copper alloys

Corrosivity usually caused by sulfur components in base oil and additives

Gear oils contain EP additives some of which can be very corrosive to yellow metals

Test procedure

Freshly polished copper strip is immersed in a test tube with 30 ml of sample and covered with a vented
stopper and heated in a bath for three hours at 212ºF

At end of test remove strip and wipe oil off and compare with standard table below

Most fluids have to have a rating of 2 or below to be acceptable

Turbine Oil Stability Test (TOST) (ASTM D-943)

Test developed to determine oxidation life of inhibited turbine oils but it is now widely used for turbine,
hydraulic, and R&O oils

Test procedure:

Tube contains catalyst coils of wound steel and copper wire

Sixty milliliters of distilled water added to bottom of tube

Three hundred ml sample is placed in the tube and immersed in a bath at 95ºC

Three liters per hour of oxygen is bubbled continuously through the sample

Neutralization number is determined until value is 2 mg of KOH per gram of oil and test terminated

Turbine Oil Stability Test (TOST) (ASTM D-943)

Test results are reported as number of hours to reach Neutralization Acid Number of 2.0

Test is stopped at 10,000 hours because of lack of sample for further titration

Values reported > 10,000 hours extrapolated from neutralization number at test termination or parallel
samples are run

Test is an indicator of oxidative life of oils and should not be used as an actual predictor of oil life

ASTM D-943 TOST TEST

Rotary Pressure Vessel Oxidation Test (ASTM D-2272)

Test previously known as Rotary Bomb Oxidation Test (RBOT)

Rapid test measured in minutes to determine

Oxidation life of lubricants having similar base stocks and additive formulations

Remaining oxidative life of in service oils

Test used to evaluate turbine, hydraulic, transformer, and gear oils

Test has poor repeatability and reproducibility and doesn’t correlate with other oxidation tests

A typical high quality turbine oil should give a minimum of 1000 minutes

Rotary Pressure Vessel Oxidation Test (ASTM D-2272)

Test procedure

Add 50 grams of an oil sample and 5 mls of water to glass vessel containing copper wire catalyst

Immerse in a pressurized oxidation cell where 5 mls of water has been added

Cell is pressurized with oxygen to 90 psi at 77ºF and placed in a preheated rotating device where the
temperature is maintained at 150ºC

Pressure readings taken until pressure levels off at ~ 192 psi

As oil oxidation occurs oxygen is absorbed and test is terminated when pressure is 25 psi less than
plateau pressure

Rotary Pressure Vessel Oxidation Test

Mitsubishi Heavy Industries Dry Tost Test

Mitsubishi Heavy Industries (MHI) developed a test to study sludge formation in turbine oils

Modified TOST test (D 943)

Run at 120ºC, without water

Tested 20 commercially available turbine oils

Passing limit: <100mg/kg @ 25% residual RPVOT

ASTM approved

TOST/ MHI DRY TOST TEST

HIGH RPVOT

HIGH RPVOT is not related to turbine oil deposit control.

Sludge is independent of initial RPVOT results

Extreme Pressure Oil Oxidation (ASTM D-2893)

Test is used to determine the high temperature oxidation stability of industrial gear oils

Test procedure

300 ml oil sample placed in a test tube which is immersed in a bath at a constant temperature of 95ºC

10 liters per hour of dry air are passed continuously through the sample for 312 hours
At the end of the test the viscosity of the oil at 100ºC is measured and compared to the viscosity of the
new oil

Extreme Pressure Oil Oxidation (ASTM D-2893)

To meet the demands of U.S. Steel Specification 224 and AGMA 9005 the test is made more severe by
elevating the test temperature to 121ºC (250ºF)

A gear oil must not exceed 6% increase in viscosity to meet the U.S. Steel 224 or AGMA 9005 standards

This is the standard test to evaluate gear oil oxidation stability and is a good relative indicator of field
performance

Foaming Characteristics Of Lubricating Oils

(ASTM D-892)

Test is a good field predictor of foaming tendencies of lubricating oils

The amount of foam after 5 minutes measures the tendency of the oil to foam

The amount of foam remaining after 10 minutes of settling measures the stability of the foam

Many specifications require no foam at the end of the 5 minute period

Foaming Characteristics Of Lubricating Oils (ASTM D-892)

Test procedure

190 ml of fluid is added to 1000 ml graduated cylinder maintained at 75ºF

Air is blown into the fluid at the rate 95 cc/min. and continued for 5 minutes

After 5 minutes air blowing is stopped and the volume of the foam is measured and recorded as
Sequence I

Foam is allowed to settle for 10 minutes and another reading of foam height is taken

The test is repeated on a second sample heated to 200ºF and the results are reported as Sequence II

Sample allowed to cool and repeated at a temperature of 75º and reported as Sequence III

Air Release Properties Of Petroleum Oils (ASTM D-3427)

Air entrainment can affect lubricant performance by causing sponginess or lack of control in turbine and
hydraulic systems

Test procedure

Add 180 ml to a specially fitted glass container

Test is run at 50ºC for oils with viscosity of 9-90 cSt or at 75ºC for viscosities > 90 cSt

Density of fluid determined with sinker attached to density balance beam

Bubble air through system at 20 kPa gauge pressure for seven minutes
Shut off air supply and immerse sinker in sample and record density

Continue density readings until sample density reaches 99.8% of initial density and record time

Terminate test after 30 minutes

Typical specifications require a maximum air release time for turbine oils as follows:

ISO 32 - 5 minutes

ISO 46 – 7 minutes

ISO 68 – 10 minutes

ASTM D-3427 AIR RELEASE TEST

Hydrolytic Stability Test (ASTM D-2619)

Test is used to evaluate the stability of hydraulic fluids in contact with water by measuring the instability
of the additives

Additive decomposition in presence of water forms insoluble salts which can block filters and orifices in
valves

Acceptable hydraulic fluids should have an acid # < 4.0 mg of KOH/gram of sample and a copper weight
loss < 0.2 mg/cm3

Test Procedure

75 grams of test oil sample and 25 grams of water are added to a six oz beverage bottle along with a
weighed copper strip

Bottle is capped and placed in a rotating device in a heated oven and rotated for 48 hours at 98.3ºC

When test is terminated the water and oil levels are separated

The following measurements are made

Acid # of water phase

Viscosity change of oil phase

Weight loss of copper strip

Water Separability Test (ASTM D-1401)

Test determines the ability of an oil to separate water

Test procedure

40 ml of lubricant and 40 ml of distilled water at 54ºC are mixed together for 5 minutes @ 1500rpm

Lubricant / water mixture is allowed to separate, and the volume of oil, water, and emulsion is recorded
at 5-minute intervals
Test is designed for oils with a maximum viscosity of 90 cSt

Water Separability Test (ASTM D-1401)

When viscosity of oil > 90 cSt the test temperature is 82ºC

Most specifications require separation no less than or equal to 3 ml of emulsion remaining after 30
minutes. Results expressed as mls. oil / mls. water / mls. emulsion

This equates very well to field performance

Demulsibility Characteristics Of Lubricating Oils (ASTM D- 2711)

Test developed to determine demulsibility of oils which experience high water contamination and
operate under turbulent conditions

Test developed for lubricants of medium to high viscosity and is used extensively for gear oils

Gear oils with good demulsibility properties usually separate more than 80 ml of water

The above testing procedure is used for other oil types where 405 ml of test oil is mixed with 45 ml of
distilled water

Test is a good field predictor of demulsibility

Test procedure for gear oils

90 ml of water and 360 ml of gear oil are stirred in a special graduated separatory funnel @ 2500 rpm
for 5 minutes at a temperature of 82.2ºC

After mixing the mixture is allowed to settle for 5 hours at the test temperature

After settling the free water is drained and measured

Amount of water remaining in the oil and emulsion phase is determined by centrifuging the oil and
emulsion layers and measuring water that has separated

Results are reported as % water in oil, total ml of free water both from funnel and centrifuging, and ml
of emulsion

Accelerated Hydraulic Fluid Pump Test (ASTM D-2882)

The test measures the antiwear performance of a fluid in a vane pump operated under severe
conditions

Test procedure

A test rig consisting of a vane pump cartridge is dismantled and the ring, vanes, and bushings are
weighed

Pump is then assembled and mounted on test rig and 10 gallons of test fluid is added

Test is operated at 1000 psi until operating temperature reaches 150ºF

Pressure is reset at 1900 psi for the remainder of the 100 hour test
After 100 hours components are disassembled and weighed

The total difference in weight of the pump parts is reported as mg of wear and overall % of wear

A high quality hydraulic oil will have 30 mg or less of wear

VICKERS 35VQ Vane Pump Test

Test demonstrates antiwear performance of a fluid in vane pump

Test procedure

Three separate vane pump test cartridges where all components are weighed are used

52 gallons of fluid @ 200ºF under 3000 psi of pressure is circulated at 38 gpm with a pump speed of
2400 rpm

The three test cartridges must meet the following criteria for the test fluid to pass

75 mg maximum cam ring weight loss

15 mg maximum vane weight loss

This not an ASTM test but is widely used by OEM’s in the evaluation of anti-wear hydraulic fluids

Four- Square Gear Test Rig (ASTM D- 5182)

Test evaluates the “scuffing” tendencies of lubricants containing mild EP additives

Test procedure

FZG test is an arrangement of two gear sets in a four-square configuration driven by an electric motor at
1450 rpm for 15 minutes

The test gear set is immersed in the test fluid at 90°C and is run at increasing loads

At each load stage the test gears are examined for any scuffing and failure is when 20% of the load
carrying flank-area of the pinion is scuffed or 10mg of weight loss.

The test can be run to a maximum of 14 stages

Four- Square Gear Test Rig (ASTM D- 5182)

Industrial gear oils require a performance level of 11 stage pass

Hydraulic oils specifications normally require a 10 stage pass

Geared turbines require an 8 stage pass

Timken Extreme Pressure Test (ASTM D-2782)

Rapid test for determining load-carrying capacity of lubricants

Typical industrial gear oils must meet a load specification of 60 lbs

Test rates various lubricants for load carrying capacity but precision is poor and results don’t correlate
well with field performance

Timken Extreme Pressure Test (ASTM D-2782)

Test procedure

Fill reservoir with three quarts of test lubricant and heat to 100ºF

Place test cup on spindle and test block in special holder

Flood test cup with lubricant and start electric motor to turn spindle @ 800rpm causing a rubbing speed
of 400 ft / min of the cup on the test block

Run the equipment for 10 minutes at increasing loads and examine the test block at each stage for
scoring and welding

Once scoring is observed the last stage achieved with no scoring is recorded as the load carrying
capacity in lbs or kg of the test fluid and this is called Timken OK load

Four Ball Ep Test (ASTM D-2783)

Four ball EP determines the load carrying capacity of a lubricant in kilograms

A quality gear oil should have a weld point of 250 kg and a minimum LWI of 45

Test procedure

Four ½ inch diameter steel balls are arranged in the form of a tetrahedron

Three lower balls are immovable in a test pot containing the lubricant to be evaluated while the fourth
rotates against them

A series of 10 second runs are made at 1760 rpm with increasing loads until welding occurs and the load
at the weld point is recorded

Four Ball Ep Test (ASTM D-2783)

Test procedure

The load wear index (LWI) is an index of the ability of a lubricant to minimize wear at applied loads and
is calculated from wear observed at different loads

The LWI can be vastly different with lubricants that have the same weld point

Four Ball Wear Test (ASTM D 4172 & 2266 MODIFIED)

The original test was D 4172 test and was modified to conform with U.S. Steel Method S-205

The original test was run at 1200 rpm while the modified wear test is run at 1800 rpm at 130°F

This test is intended to rate the wear performance of lubricants under different loads and is a good field
predictor

Typically a high quality gear oil should not exceed 0.35 mm in scar diameter
Typically hydraulic oils should have an average scar diameter of 0.50 – 0.80 mm

Test procedure

Test conducted similar to EP four ball test

Balls are loaded against one and other with a force of 20 kg for EP gear oils and 40 kg for other fluids
with the top ball rotating at 1800 rpm for 60 minutes

At the end of the test , the three lower balls are observed for scarring and the average scar diameter of
the three balls is recorded

Dielectric Strength ASTM D-877

Determines resistance of a fluid, called dielectric strength, to an electric arc passing through it

Standard test for insulating oils

Results measured in KV(kilovolts)

Higher the number more resistant fluid is to electrical conductivity.

New insulating oil should have minimum dielectric strength of 30 KV

ISO 4406 FLUID CLEANLINESS

The ISO cleanliness code is the most common method to express fluid cleanliness

Three ways to count and size particles

Microscope

Automatic optical particle counting

Automatic pore blockage particle counting

Automatic optical is the most common method for particle counting

Not effective for high viscosity and colored fluids

Emulsified water cause interference with particle readings

ISO 4406 CLEANLINESS CODE

Expressed as x/x/x 16/14/11

16 --->4 µ[c]

14---> 6 µ[c]

11--->14 µ [c]

Old system was:

---> 2 --->5 --->15

ISO 4406 CLEANLINESS CODE

OEM Specification Requirements

Ge Turbine Oil Specifications

Siemens Turbine Oil Specifications

Evaluation Of Selected Turbine Oils

Composite Hydraulic OEM Specifications

Evaluation Of Selected Hydraulic Oils

Industrial EP Gear Requirements

Evaluation Of Selected Gear Oils

Classification and Properties of Oils

Functions of a Lubricating Oil

Lubrication

Provide a film between moving parts

Cooling

Heat transfer media

Sealing

Filling in uneven surfaces

Cleaning

Holding contaminants in suspension

Dampening & Cushioning

Of components under high stress

Protection

From oxidation & corrosion

Fractional Distillation

Base Oil Groups

Group I

<90 percent saturates, >0.03 % sulfur . Solvent refined, which is a simple refining process.

Group II

> 90 percent saturates, <0.03 % sulfur . Often hydrocracked, using pressure and heat.

Group III

>90 percent saturates, <0.03 % sulfur . Generally are severely hydrocracked (higher pressure and heat).
Group III base oils are sometimes described as synthesized hydrocarbons (US).

Base Oil Groups

Group IV

Group IV base oils are polyalphaolefins (PAOs). These synthetic base oils are made through a process
called synthesizing. They have a much broader temperature range and are great for use in extreme cold
conditions and high heat applications.

Group V

Group V base oils are classified as all other base oils, including silicone, phosphate ester, polyalkylene
glycol (PAG), polyolester, biolubes.

Properties of Oil

Viscosity

Viscosity Index

Pour Point

Demulsibility

Oxidation Resistance

Thermal Stability

Viscosity – ISO System

Viscosity – SAE System

Mono Grade V Multi Grade

Viscosity Index

The relationship of viscosity and temperature is defined by the Viscosity Index

The majority of oils have a VI of about 100 (a unitless number on an arbitrary scale).

To determine the VI of an oil, its viscosity must be measured at 40 and 100 degrees C. and from these
readings and a set of tables published by the ASTM, its VI can be calculated.

Viscosity Index

VI 80 ~ 110 – Mono Grade Mineral Oil

VI 120 ~ 140 – Multi Grade Oil

VI >160 – Synthetic Oils

Demulsibility

Oils that separate readily from water have good demulsibility

Oil and water have a natural tendency to separate.

Oils with good demulsibility that are given ample time to settle will allow for the separation of the water
which can be drained from the bottom of the reservoir.

Oxidation Resistance

Oils will oxidise in the presence of oxygen. High temperatures accelerate oxidation

The graph above illustrates the dramatic effect that temperature plays on oil oxidation. For every 10°C
increase in operating temperature, the rate of oxidation doubles.

Thermal Stability

Mineral oils exhibit thermal stability up to 350°Celcius

The graph above illustrates the dramatic effect that temperature plays on an oils life. For a typical
mineral oil, the life of the oil can be reduced from 50,000 hrs to just 1 hr going from 287C to 410C

Additives

Surface Protective

Detergents

Dispersants

Rust and Corrosion Inhibitors

Anti Wear and EP Agents

Friction Modifiers

Performance

Seal Swell Agent

Viscosity Improver

Pour Point Depressant

Lubricant Protective

Antifoam

Antioxidants

Emulsifying and Demulsifying Agents

Metal Deactivator

Detergents

Purpose

Keep surfaces free of deposits

Typical Components
Metallo-organic compounds of sodium, calcium and magnesium phenolates, phosphonates and
sulfonates

Functions

Chemical reaction with sludge and varnish precursors to neutralize them and keep them soluble

Dispersants

Purpose

One end of these additives are soluble in oil and the other attracts dirt, sludge and other contaminants
and holds them in suspension in the oil.

Typical Compounds

Alkylsuccinimides, alkylsuccinic esters, and mannich reaction products

Functions

Contaminants are bonded by polar attraction to dispersant molecules, prevented from agglomerating
and kept in suspension due to solubility of dispersant

Dispersants

Purpose

Prevent corrosion and rusting of metal parts in contact with the lubricant

Typical Compounds

Zinc dithiophosphates, metal phenolates, basic metal sulfonates, fatty acids and amines

Functions

Preferential absorption of polar constituent on metal surface to provide protective film, or neutralize
corrosive acids

Friction Modifiers

Purpose

To minimise light surface contacts (sliding and rolling) that may occur in a given machine design. These
are also called boundary lubrication additives

Typical Compounds

Organic fatty acids and amides, lard oil, high molecular weight organic phosphorus and phosphoric acid
esters

Functions

To provide a cushioning effect when one of the coated surfaces connects with another coated surface

Friction Modifiers
Purpose

Reduce friction and wear and prevent scoring and seizure

Typical Compounds

Zinc dithiophosphates, organic phosphates, acid phosphates, organic sulfur and chlorine compounds,
sulfurized fats, sulfides and disulfides

Functions

Chemical reaction with metal surface to form a film with lower shear strength than the metal, thereby
preventing metal-to-metal contact

Fractional Distillation

Gear Oil Classification - API

API “GL” 1 through to 6

Different applications require different “GL” ratings

Depending on gearbox type or design

Different designs require different additive levels

Gear Oil Classification - API

Gear Oils – API Specifications

GL-1 Some manual gearboxes, no additives, straight mineral

GL-2 Worm drive gear boxes, contains fatty acid (excellent for load carrying)

GL-3 Manual gear boxes and spiral bevel axles in moderate applications – mild EP

GL-4 Gear boxes & spiral bevel and hypoid axles in moderate to severe applications – EP (about 50% of
GL 5 level)

GL-5 Hypoid axles in severe applications eg high speed or low speed - high torque – most truck diffs

Seal Swell Agents

Purpose

Swell elastomeric seals

Typical Compounds

Organic phosphates and aromatic hydrocarbons

Functions

Chemical reaction with elastomer to cause slight swell

Viscosity Modifiers
Purpose

Reduce the rate of viscosity change with temperature

Typical Compounds

Polymers and copolymers of olefins, methacrylates, dienes or alkylated styrenes

Functions

Polymers expand with increasing temperature to counteract oil thinning

Pour Point Depressant

Purpose

Enable lubricant to flow at low temperatures

Typical Compounds

Alkylated naphthalene and phenolic polymers, polymethacrylates, maleate/fumerate copolymer esters

Functions

Modify wax crystal formation to reduce interlocking

Anti-Foaming Agents

Purpose

Prevent lubricant from forming a persistent foam

Typical Compounds

Silicone polymers, organic copolymers

Functions

Reduces surface tension to speed collapse of foam

Metal Deactivator

Purpose

Reduce catalytic effect of metals on oxidation rate

Typical Compounds

Organic complexes containing nitrogen or sulfur, amines, sulfides and phosphites

Functions

Form inactive film on metal surfaces by complexing with metallic ions

Demulsifying Agents

Purpose
Hydrophilic surfactants chelate (trap) water droplets in the oil.

Typical Compounds

Assist in coalescing water droplets so that they drop out of the oil and increase the ability of water and
oil to separate at the oil/water interface.

Functions

Promote the formation of a stable mixture of oil and water

Anti Oxidant

Purpose

Retard oxidative decomposition

Typical Compounds

Zinc dithiophosphates, hindered phenols, aromatic amines, sulfurised phenols

Functions

Decompose peroxides and terminate free-radical reactions

Synthetic Oils

Low pour point

High viscosity index

High flash point / fire resistance

Oxidatitive and thermal stability

High shear strength

Functions of a Lubricating Oil

Lubrication

Provide a film between moving parts

Cooling

Heat transfer media

Sealing

Filling in uneven surfaces

Cleaning

Holding contaminants in suspension

Dampening & Cushioning

Of components under high stress

Protection

From oxidation & corrosion