Teori dan Dasar Pelumasan

Outline Presentation
1. Fundamentals of tribology
2. Functions of a lubricant
3. Lubrication regimes
a) Hydrodynamic
b) Elasto-hydrodynamic
c) Boundary
4. Base Oils
a) Functions
b) Properties
c) Characteristics, advantages & disadvantages
 Outline Presentation
5. Additives functions
a) Antioxidants/oxidation inhibitors
b) Rust inhibitors
c) Corrosion inhibitors
d) Demulsifying agents
e) Viscosity index (VI) improvers
f) Detergents
g) Dispersants
h) Pour-point depressants
i) Foam inhibitors
j) Anti-wear (AW) agents
k) Extreme pressure (EP) agents
 Outline Presentation
6. Oil lubricant physical, chemical and performance properties and
classifications
7. Grease lubrication
a) How grease is made
b) Thickener types
c) Thickener compatibility
d) Grease lubricant physical, chemical and performance properties
and classifications

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Lubricating Oil Functions
Friction Control
Wear Control
Corrosion Control
Temperature Control
Contamination Control
Power Transmission
Reference: NORIA
Reduce heat generation and
Energy consumption
Reduce Mechanical and
corrosive wear
Protect surfaces from corrosive
subtances
Absorp and transfer heat
Tranports particles and
contaminants to filters
In hydraulics
Ref : JCF
Types of Lubrications

Film
Regime Thickness, Common
Fluid film lubrication micro-inches Examples

Hydrodynamic 100 - 3000 Journal bearings

Mixed Film 10 – 50 Ball bearings,

Roller bearings
Mixed film lubrication
Boundary 0.08 – 0.4 Gear

Boundary
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Hydrodynamic Lubrication
• Occurs when machine parts are completely separated by a full
and continuous film of lubricant
• Contact between the parts does not occur.
• Full-fluid-film lubrication is hydrodynamic lubrication, the oil
adheres to the moving part and is drawn into the area
between the rotating surfaces, where it forms a pressure, or
hydrodynamic, wedge.
• A less common form of full-fluid-lubrication is hydrostatic
lubrication, where the oil is supplied to the bearing area
under pressure to separate the sliding surfaces.
Hydrodynamic Lubrication

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Boundary Lubrication
• Under certain conditions such as shock loading, heavy loads,
high temperature, slow speed and critically low viscosity, the
lubricant is no longer hydrodynamic
• Frequent contact between the surfaces, resulting in a
significant rise in temperature and subsequent destruction of
the contacting surfaces.
• Under these circumstances, the fluid film is no longer capable
of adequately protecting the surfaces.
• EP capabilities in the lubricant are essential
• Solid additives are mixed into the grease
Mixed Lubrication or
Elastohydrodinamic
• Although not a true “mode” of lubrication in the sense of
hydrodynamic or boundary, mixed lubrication occurs more
frequently then is realized.
• Mixed lubrication is a transitional mode of lubrication
between hydrodynamic and boundary
• Mixed lubrication is characterized by the likelihood of
intermittent surface contact
• EP and anti-wear are essential properties in the lubricant
How is a lubricant are made?
Base Oil Additives
Mineral or Synthetic Organic and Inorganic

1) Mengatur kekentalan 1) Memperbaiki karakteristik

pelumas base oil

2) Memberikan ketahanan 2) Mengurangi karakteristik

terhadap oksidasi dan korosi base oil yang tidak
diinginkan
3) Memberikan kemampuan
menyerap atau menyalurkan 3) Memberikan base oil
kalor kemampuan baru atau lebih
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 What is a Base Oil?
The refined petroleum mineral or synthetic
material that is produced by a refinery to a
required set of specifications.
• A lubricant’s quality can depend upon:
– Type of base oil used or
– Refining and/ or production method used to produce
the base oil .
• Base oils normally make up 70% to 99% of a
lubricant’s formulation
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Common Generic Lubricant Types
Oil Types Description Example uses
R&O Rust and oxidation Oil Bearing,
Also commonly contain defoamate, demusifying agents, Tubine oils
and corrosion inhibitors

AW Lubricating oils with anti-wear (AW) additives Hydraulic

Usually contain similar additives to R&O oils as well as AW fluids
EP Lubricating oils with extreme pressure (EP) Gear oils
additives
Usually contain similar additives to R&O oils as well as AW

COMP Compounded oils containing synthetic fatty- Worm gear oil

acid lubricity agents
Motor Oil Anti-wear detergent and dispersant Internal
combastion
Engine oils

PETROLAB Laboratory Reference: NORIA

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Base Oils
Mineral Synthetic Bio-based

Lubricant Performace depends largely on the quality

and properties of base oils

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Base Stock Physical Properties
Viscometric
Viscosity
●

VI
●

Pour point
●

Saturates

Oxidation Stability
●

Sulfur
●

Nitrogent
●

Volatility Noack
●

●
Flash point

Compatibility
Seal swell/shrink
●

Additive solubility
●

Mixibility
●

Safety Flash point

●

●
Toxicity

Consistency ●
Batch to batch

• Color
Appearance • Cleanliness
• clarity

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Mineral Base Oils
Crude oil derivative. Properties depend on the quality of crude stock and refining process

Mineral % % % % %
Base Oil Paraffins Nephthanes Aromatic % Wax Asphalt Sulfur
Paraffinic 45-60 20-30 15-25 1-10 0-5 0.5
Naphthenic 15-25 65-75 ~10 Trace 0-5 1
Aromatic ~5 60-75 20-25 0-0.5 0-20 -

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 Mineral Oil Properties
Spec.Grav.@ sulfur % Kinematic Vis. cSt Pour Flash Point
16C by wt VI 40 C 100 C Point C C
100 Neutral 0.860 0.065 101 20.39 4.11 -13 192
200 Neutral 0.872 0.096 99 40.74 6.23 -20 226
350 Neutral 0.877 0.126 97 65.59 8.39 -18 252
650 Neutral 0.882 0.155 96 117.90 12.43 -18 272
150 Bright Stock 0.895 0.263 95 438.00 29.46 -18 302

Naphthenic
Naphthenic Paraffinic

Narrow Operating Temperature Range Wide Operating Temperature Range

Low Viscosity Index High Viscosity Index
Low Pour Point High Pour Point
Low Flash Point Contains Wax
Rare Many
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Mineral Oil Properties
Paraffinic Naphthenic
Crude Oil Mid Continent, North Sea, Middle east South American, Coastal Regions of US
% Paraffins 45-60 15-25
% Naphthenes 20-30 65-75
% Wax 1-10 30-70
VI 95-105 30-70
Pour Point Wax pour point Lower, viscosity pour point
Flash point Higher Lower
Additive Solvency Poor to fair Good
Applications Crankcase oil Locomotive engine oils
Hydraulic Oils Refrigerant oils
Turbine oils Compressor oils
Gear oils
Bearing oils

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 API Base Oil Categories
HC Saturates Viscosity
Base Oil Category Sulfur (%)  
(%) Index
and/o
Group I >0.03 <90 80 to 120
r
Group II <0.03 and >90 80 to 120
Group III <0.03 and >90 >120
Group IV All polyalphaolefins (PAOs)
All others not included in Groups I, II, III or IV
Group V
(Esters)

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Synthetic Lubricants

• Scientifically designed molecules

• Molecules have identified structure
• Fluid properties are very predictable
• Made by polymerization

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 Molecular Comparison
Between Mineral and Synthetic Oil
30
Mineral Property Synthetic 30

Number
Number

Millions of Molecule Molecules repeat

combination Structure

Varies greatly Molecule Size Constant

(weight)

Contains aromatic, Purity Very pure

0 nitrogen, sulfur, wax 0
0 Size (Weight) 50 0 50
Size (Weight)

Oxidation Stability
More
stable Polyalphaolefin (Synthetic)
Group III
Group II
Group I
Naphthenic Mineral Oil

Mineral Oil Synthetic Oil

Less
Stable Aromatic Mineral Oil

Reference: NORIA
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Synthesized hydrocarbons
• polyalphaolefins,
• alkylated aromatics,
• polybutenes,
• aliphatic diesters,
• polyolesters,
• polyalkylene glycols,
• phosphate esters.

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Polyalphaolefins - PAO
Properties

• Similar to branced Paraffins

• Contains no S, P, wax or metals
• High Viscosity Index
• Excellent low temperature fluidity
• Low pour point
• Good oxidation stability
• Low volatility
• Compatible with mineral oils
• Low solubility for ammonia and refrigerant 22
Polyalphaolefins - PAO
Applications
• Engine oils
• Automotive gear oils
• Industrial gear and bearing ois
• Hydraulic fluids
• Grease
Disadvantages
• Limited ability to dissolve some additive
• Tend to shrink rubber, seals, and hoses
• Require suitable anti-oxidant
• Limited properties on boundary lubrication
Di-Basic Acid Ester
Properties
• Contains no S, P, wax or metals
• High Viscosity Index
• Excellent low temperature fluidity
• Low pour point
• Good oxidation and thermal stability
• Low volatility
• Tend to dissolve varnish and slugde deposits
Di-Basic Acid Ester
Disadvantages
• Poor hydrolitic stability
• Tend to swell seals
• Requir special additive
• Affect paints and
finishes
• Poor water/oil
demulsibility
• Poor anti-rust
performance
Applications
• Type I Jet engine oils
• Compressor oils
• High temperature grease
• Component of Synthetic
base oil blend for
automotive engine oils
Polyol Esters
Properties
• Contains no S, P, wax or metals
• High Viscosity Index
• Excellent low temperature fluidity
• Low pour point (-30 to -70)
• Good oxidation stability
• Lower volatility
• Tend to dissolve varnish and slugde deposits
• Excellent thermal stability
• Better hydrolytic stability

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Polyol Esters
Disadvantage
• Tend to swell seals
• Requir special additive
• Affect paints and finishes
• Compatibility only with
polyol esters
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Applications
• Second generation jet engine
oil (type II)
• Compressor lubricsnts
• Blends for aoutomotive
engine oils
• High temperature gear
lubricants
• Base oil for wide
temperature range greases
Phosphate Esters
Properties
• Excellent fire resistance
• Good thermal stability
• Low pour point (-25 to -5 oC)
• Excellent boundary lubrication properties
• Low volatility
• Fair hydrolytic stability
• Specific gravity greater than 1

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Phosphate Esters
Disadvantage
• Low viscosity Indx
• Limited capabilities at high temperature
• Decomposition product are coorosive
• Poor compatibility with mineral oils
• Electrokinetic erosion in valve due to AN increase and chlorine
contamination
• Degradation product are phosphate soap; balck sludge-like consistency

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Phosphate Esters
Applications
• Fire-resistant industrial hydraulic fluid
• Hydraulic fluid for hydraulic aviaton system
• Electrohydraulic control fluids for steam turbines
(EHC)
• Used as turbine bearing lubrication systems
• Used as wear and friction reducing additives in
greases

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Polyalkylene Glycol
Properties
• wide viscosity range,
• excellent viscosity/temperature characteristics,
• low pour points,
• good thermal stability,
• high flash points,
• good lubricity,
• low toxicity,
• good shear stability,
• water solubility or insolubility,
• non-corrosive to common metals,
• volatile or soluble breakdown products,
• little effect on rubbers,
• practically non-flammable in aqueous solution

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Polyalkylene Glycol
Disadvantages
• Poor performance at low
temperature
• Not compatible with mineral oil
and their additives
• Not compatible with PAOs or
esters
• Considerable compatility risk
with paint and finishes
• 6-8 times more expensive than
mineral oils
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Applications
• Hydraulic brake fluids
• Metal working fluid
• Het transfer fluids
• High temperature hydraulic
fluids
• Srew refrigerant compressors
and hydrokarbon gases
• Screw type compressors
handling hydrocarbon gases
Silicones
Properties
• Very high VI (300 or more)
• Chemically inert
• Non-toxic
• Low temperature fluidity
• Fire-resistant
• Low volatility
• Good thermal and oxidation stability

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Silicones
Disadvantages Applications
• High compressibility • Wide temperature range
• Oxidation product are • High temperature oils and
abrasive (SiO2) greases
• Low surface tension • Lubrication exposed to
• Poor antiwear protection radiation or oxygent
• Poor additives response • Specialty hydraulic applicatons
requring compressible fluid
• Brake fluids

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 Temperature Range oil Service
o
C -75 -50 -25 0 100 150 200 250 300
350
o
F -103 -58 -13 32 212 302 392 482 572
662 Mineral Oil
Type The detail here
Di-Esters
Perfluorinated Aliphatic Ethers (PFAE)
Phospate Ester
Polyalphaolefins (PAO)
Polyglycols (PAG)
Polyol Esters
Polyphenyl Esters
Silicons

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 Performance of Base Stock

Chlorinated Hydrocaron

Synthetic Hydrocarbon

Dialkylated Benzene
Perfluorpolyether

Phosphate Ester

Alkylated Aromatic
E - EXCELLENT

Polyalphaolefin
G - GOOD

Silicate Ester
P - POOR

Polyol Ester

Mineral Oil
Polyglycol
VL- VERY LOW

Di-ester
Silicone
L - LOW
M - MEDIUM
H - HIGH
VH-VERY HIGH
NA-NOT AVAILABLE
Temperature Range G E E F G F G E F G G F
P
Pour Point L VL L L L M G VL H VL VL G F
Flash Point G E E F G F E E F E E G M
Viscosity Range H VH H M M H H H M M H NA L
Oxidation Stability G E E F G G G G E G NA NA P

Corrosion Stability E F P P P F G F G G E NA
Compatible with E
E P P F F P P P NA G NA E
Mineral Oil -
Seal Compatibility G G G P P F P P P G NA F
L

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 Additives
Deposit Control Additives

Antiwear Additives Film-Forming Additives

Extreme-Pressure Additives
Viscosity Control Additives

Corrosion Inhibitors and Rust Preventatives

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Additive: What They Are
• Organic and
inoranic
compound
dissolve or
suspended in oil
• Present from
0.1% to 30%
• Monitoring
additive health is
important goal
of oil analysis

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Additives Function
Anti-oxidants
Enhanced Corrosion inhibitors
Existing Base
Oil Propertis Anti-foam agents
Demulsifying agents

Suppress Pour point Depressants

Undesirable
Base Oil VI Improvers
Properties
EP Additives
Detergents
Impart New
Properties Metal Deactivators
Tackiness Agent

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Characteristics of Polar Additives
Polarity: is a separation of electric charge leading to a molecule or its chemical
group having an electric dipole or multipole moment
Polar Materaial: Non-polar material:
Water, sponge, glass, Teflon, mineral oil base
dirt, metal surface, stock, wax, duck’s back,
wood pulp water repellents

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 How Polar Additive Work
Polar Mechanism What’s going on Additives

Particle Enveloping Additive cling to Metal deactivators,

particle surface detergents,
dispersant

Water Emulsifying Polar head cling to Emulsifying agents

microdroplet of
moisture

Metal Wetting Additives anchor to Rust inhibitor, AW

metal surface and, EP additives,
oilliness agents, and
corrosion inhibitors

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AW and Friction Control Additives

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 AW and Friction Control Additives
Oilliness agent AW additives EP Additives

Description Highly polar, organic, Polar metal wetting 1) Chemically

metal wetting additives. additive. Usually aggressivesulfurphosphoru
Form ductile adherent produced from zinc s. Form adherentsurface
film: a microscopic salt, P, and S. Form film that transforms to
carpet. Under load a ductile ash-like film at ductile metal soap under
mtal soap result. Not moderate to high high load
effective at contact contact temp (150 – 2) Suspention in base oil. The
temp. >150 oF. 230 oF). Light solid form tough wear
chemical wear. resistant boundary film.

Commmon Fatty Acid ZDDP, TCP 1) Sulfur phosphorus EP

additives 2) Borate, MoS2, graphite

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 Antioxidants
Role of How They Work Common types
Antioxidant
To prevent the Antioxidant ZDDP; peroxide decomposer and metal
formation of acid, decompose reactive deactivator
varnish, sludge and hydroperoxides and Hindered phenol; chain breaking
high viscosity . free radicals before Aromatic amines; Radical trap
they lead to Metal Salysilate and phenate; Metal
oxidation deactivator

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 Dispersant
Maximazing soot particle hang time with prevent soot particle to agglomerate

Maeterial used: succunamides and other organic compound

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Presentation Title

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Viscosity Index Improvers
Description:
Long chain organic molecules
mixed into base oil. Used to
increase VI for muti-grade
lubricant.
Material Used:
• Radial polyisoprene
• Polyisobuthylene (PIB)
• Polymethacrylate (PMA)
• Olefin co-polymers (OCP)

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How VI Improver Work

SAE Grade Approximate Viscosity (cSt)

0oC 100oC 120oC
30 2,500 12.0 7.5
10W-30 450 12.0 8.5

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 Over-base Detergents Additives
Description
Detergent work at the higher-temperature
combat zone of the engine to keep surface free
of the deposits, especially at ring grooves.
Detergent are also overbased to neutralize
Harmful acids generated by combustion
Compound
Organometallic soaps of barium,
calcium and magnesium. Detergent are
alkali containing phenate and
sulfonates. Magnesium Oxide are
abrasive.

Functions:
• Deposit control
• Acid neutralization

O2 H2O
S + O2 SO2 SO3 H2SO4
Poor Deposit Control

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Anti-foam

Type The detail here

• Compound used include methyl silicon and polymethacrylate (PMA)

• Suspended in micro-globue (about 10 microns). Silicon are commonly used in
engine oil at 10-50 ppm. PMA used in other applications at 100-200 ppm
• Bubbles weaken if there is high interfacial tension between the oil (30-
35dynes/cm and defoamant (20-24 dynes/cm)
• Water, soap, lower an oil’s surface tension, reducing performance of defoamants

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Lubricating Grease
According to the classical ASTM definition:
lubricating grease is ‘a solid to semifluid
product of a thickening agent in a liquid lubricant, other ingredients
imparting
special properties may be included’.

A more rhelogically based definition is:

a lubricant which under certain loads and within its range of temperature
application, exhibits the properties of a solid body, undergoes plastic strain
and starts to flow like a liquid should the load reach the critical point, and
regains solid body like properties after the removal of stress

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Anatomy of a Lubricating Grease
Grease

Additive
Buyer
Buyer Thickener
Seller
Seller Fluid
Seller Lubricant
Seller

Antioxidant Soap Petroleum Oils

Antiwear Lithium, Sodium, Barium, Polyalpha Olefins (PAO)
Antirust Calcium, Aluminum Polybuthenes
Anticorrosion Esters
Extreme pressure Non-Soap (inorganic) Polyglycols
VI Improver Clay, Graphite, Silica Polyseters
Tackifier Carbon Black Silicones
Pour Point Depressant Non-Soap (organic) PFPE
Solid Boundary Lubricants
Dye Polyurea, PTFE, Wax

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Grease Advantages
Using greases for lubrication has some
advantages:
• Greases stay put
• Greases seal out contaminants
• Greases do not need circulation systems
• Greases decrease dripping, splattering and leakage
• Greases suspend solid additives easily
• Greases are suitable for intermittent operations
• Greases work under extreme operating conditions
• Greases seal for life
• Greases reduce noise
• Greased machinery tends to need less power

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Grease Disadvantages
Greases may also bear some disadvantages:
• Greases may not reach all places in need of lubrication
• Greases do not have any cleaning effect
• Greases do not work as cooling agent
• Greases cannot be used at as high speeds as liquids

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Properties of Different Thickeners
Salt
Max Wate Ru
Ther Wate Shea Oxid Oil
Usab r st Pum
mal Lubri r r ation Sepa
le Resi Pro pabi
Stab city Resi Stabi Stabi ratio
Tem stan tect lity
ility stan lity lity n
p °F ce ion
ce
Aluminum, conventional 175
Aluminum, complex 350
Calcium, conventional 200
Calcium, anhydrous 230
Calcium, complex 350
Lithium, conventional 275
Lithium, complex 350
Polyurea 350
Organo-clay 350
Sodium 350

Excellent Good Fair Poor

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 Grease Compatibility Chart
Alumi Calciu Calciu Lithi Lithiu
num Bariu Calciu m m Lithiu um m Polyu
Clay
Compl m m Compl m Com rea
ex -Hydr ex -Hyd plex
oxy roxy
Aluminum Complex C I I C I I B B C B
Barium I C I C I I I I I I
Calcium I I C C I C C B C I
Calcium 12-Hydroxy C C C C C C C C C I
Calcium Complex I I I B C I I I C C
Clay I I C C I C I I I I
Lithium B I C C I I C C C I
Lithium 12-Hydroxy B I B C I I C C C I
Lithium Complex C I C C C I C C C I
Polyurea B I I I C I I I I C
C = Usually compatible.
B = Borderline compatibility (probably incompatible). Note: Not all polyurea grease are mutually compatible
I = Incompatible

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Grease Consistency

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Common Test Equipment
Cone Penetrometer Grease Worker

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Typical Grease Tests
Test ASTM Test Description
Method
Cone Penetration D-217 Depth a “cone” pushes into grease
Dropping Point D-2265 Temperature where grease “melts”
Apparent Viscosity D-1092 “Thickness” of grease
4 Ball Wear D-2266 Apply load until balls weld
Evaporation D-972 Weight loss from grease
Copper Corrosion D-4048 Chemical reactivity with metal
Water Washout D-1264 Removal of grease by water
Rust Resistance D-1743 Protection of iron & steels
Oxidation Stability D-942 Storage stability

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NLGI grease classification
NLGI ASTM Consistency Approxim
Number Worked ate %
Penetration Thickener
000 445 - 475 Semi-fluid (Ketchup)
00 400 - 430 Semi-fluid (Applesauce)
0 355 – 385 Very soft (Deli Mustard) 9
1 310 – 340 Soft (Tomato Paste) 11
2 265 – 295 Common Grease (Peanut Butter) 14
3 220 – 250 Semi-hard (Solid Shortening) 23
4 175 – 205 Hard (Frozen Yogurt) 27
5 130 – 160 Very Hard (Hard Butter) 32
6 85 - 115 Solid (Brick Cheddar Cheese) 40

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Factor that Influence Grease
Consistency
Formulation Field Condition

Temperature
Base Oil viscosity
Agitation

Thickener Type Contamination

Pressure
Thickener
Concentration
Beed & Oxidation

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Selecting Grease According to Consistency
and Base Oil Viscosity

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What Causes Grease Dry-out?
Contamination:
• Dirt, dust, fly ash, etc
Bleed:
• Centrifugation
• Incompatible grease
• Wring-out
Volatilization:
• High temperature
• High temperature
• Incompatible grease
• Low flash point
• Low-quality grease
• Cracking • Vibration
Oxidation: • Low-base oil viscosity
• Heat
• Water
• Wear metals
• Low-quality grease
• Gamma radiation

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Viscosity
Influence by: An Oil’s Resistance to
• Temperature Flow and Shear
• Water
• Contaminant
• Chemical change
• Pressure
• Shear

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Measures for Viscosity
Absolute Viscosity Kinematic Viscosity
An Oil’s resistance to flow
An Oil’s resistance to flow
and shear (internal friction)
and shear by the forces of
gravity
Common unit; centipose (cP)
(mPa*s)
Common unit; centistokes (cSt)
(mm2/s)

Absolute viscosity = Kinematic Viscosity X Density

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Kinematic Viscosity Measurement

Kinematic Viscosity =
Apparatus Constant x
Efflux Time

Unit - centistokes

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 Absolute Viscosity Measurement
• Torque of spindel
determines viscosity in
centipose (cPs)

• Glass tube required

• Good for low-

temperature testing

• Good for laboratory

used oil monitoring

Rotary viscometer

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ISO Viscosity Grade

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SAE-J300 Engine Oil Viscosity Classification

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SAE-J306 Gear Oil Viscosity Classification

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Comparative Viscosity Classification

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Viscosity/Temperature Chart

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 What is Viscosity Index
Viscosity index (VI) is an arbitrary measure for the change of viscosity with
variations in temperature. The lower the VI, the greater the change of
viscosity of the oil with temperature and vice versa.

PETROLAB Laboratory
www.petrolab.co.id
 Typical VI of Oils
VI -20 to 0 0 to 60 60 to 100 100 to 200
Type oils Some phosphate Naphtenic Paraffinic VI improved mineral
esters mineral oils mineral oils oils, and syhthetics

PETROLAB Laboratory
www.petrolab.co.id
Thanks for your attention