Lubricants

Although many functional characteristics, such as fatigue life and damage resistance depend on residual stresses, there are currently no industrially viable ‘Digital Process Twin’ models (DPTs) capable of efficiently and quickly predicting machining-induced stresses. By leveraging advances in ultra-high-speed in-situ experimental characterization of machining and finishing processes under plane strain (orthogonal/2D) conditions, we have developed a set of physics-based semi-analytical models to predict residual stress evolution in light of the extreme gradients of stress, strain and temperature, which are unique to these thermo-mechanical processes. Initial validation trials of this novel paradigm were carried out in Ti-6Al4V and AISI 4340 alloy steel. A variety dry, cryogenically cooled and oil lubricated conditions were evaluated to determine the model’s ability to capture the tribological changes induced due to lubrication and cooling. The preliminarily calibrated and validated model exhibited an average correlation of better than 20% between the predicted stresses and experimental data, with calculation times of less than a second. Based on such fast-acting DPTs, the authors envision future capabilities in pro-active surface engineering of advanced structural components (e.g., turbine blades). Full article

In the present investigation, in-situ epoxidation of waste cooking oil and its methyl esters was prepared, and the rheological behavior was analyzed for biolubricant applications. Rheological properties of the prepared epoxides were measured at a temperature of 25–100 °C, at a shear rate ranging from 5 to 300 s⁻¹. As viscosity is one of the critical parameters for potential biolubricant applications, in the present study, the power-law model was used to investigate the flow behavior of the epoxides. The viscosity of epoxidized waste cooking oil and its methyl ester epoxides showed Newtonian flow behavior in the studied temperature range. Different shear rates (5–100, 5–300, 100–300 s⁻¹) were studied to determine the shear rate dependency of the epoxidized waste cooking oil and its methyl ester epoxides at different temperatures. From the average viscosity values, it was shown that the epoxides show identical results at all shear rates. The dynamic viscosities of the epoxidized waste cooking oil and its methyl ester epoxides were found to be dependent on fatty acid chain length, unsaturation, and temperature. Detailed physicochemical characterization for epoxide waste cooking oil (EWCO) and epoxide waste cooking oil methyl esters (EWCOME) were carried out to evaluate the properties for suitable biolubricant applications using standard American Society for Testing and Materials (ASTM) and American Oil Chemists’ Society (AOCS) methods. Based on the viscosity for EWCO (278.9 mm²/s) and EWCOME (12.15 mm²/s) and viscosity index for EWCO (164.94) and EWCOME (151.97) of the prepared epoxides, they could complement the standard ISO vegetable grade (VG) lubricants in the market. Full article

In tilting-pad journal bearings (TPJB) with a non-flooded lubrication concept, higher maximum pad temperatures occur than with a flooded bearing design due to the lower convective heat transfer at the pad edges. In this paper, we present an approach to influence the thermal behavior of a five-pad TPJB by active cooling. The aim of this research is to investigate the influence of additional oil supply grooves at the trailing edge of the two loaded pads on the maximum pad temperature of a large TPJB in non-flooded design. We carry out experimental and numerical investigations for a redesigned test bearing. Within the experimental analysis, the reduction in pad temperature is quantified. A simulation model of the bearing is synthesized with respect to the additional oil supply grooves. The simulation results are compared with the experimental data to derive heat transfer coefficients for the pad surfaces. The experimental results indicate a considerable reduction of the maximum pad temperatures. An overall lower temperature level is observed for the rear pad in circumferential direction (pad 4). The authors attribute this effect by a cooling oil carry-over from the previous pad (3). Within the model limits, a good agreement of the simulation and experimental results can be found. Full article

Internal combustion engines are widely implemented in several applications; however, they still face significant challenges due to the sealing capacity of the compression rings. Gas leakage through the crankcase, also known as blow-by, directly impacts power losses, overall efficiency, and global emissions. Therefore, the present study investigates the influence of parameters such as the ring gap, ring masses, and twist angle of the compression rings on the sealing capacity of the combustion chamber. A mathematical model is proposed to account for geometric, dynamic, and operational characteristics in a single-cylinder diesel engine. The results indicated that the greatest gas losses to the crankcase occur during the compression and combustion stages as a consequence of extreme pressure conditions. Specifically, at least 0.5% of the gases locked in the combustion chamber are released on each cycle, while increasing the mass of the compression rings boosts the gas leakage due to higher inertial forces in the rings. In contrast, a positive twist angle of the compression rings reduced the combustion gases leakage by . Additionally, a combined reduction in the gap of both compression rings minimized the leakage flows by 37%. In conclusion, the proposed model served as a robust tool to evaluate different parameters on the sealing capacity of the combustion chamber that contribute to minimizing global emissions. Secondary piston motion and ring distortion represent significant opportunities in future studies. Full article

In most gear drive applications mineral or synthetic oils are used as lubricants, which are made of fossil raw materials and are non-biodegradable. In applications located in critical environmental areas such as boats or harbors, eco-friendly lubricants are needed. As a result, a gear transmission fluid based on water is currently being developed in a research project supported by the Bayrische Forschungsstiftung (Bavarian Research Foundation). Results of former research showed that in general it is possible to use water-based lubricants in gear drives under certain operating conditions. Since water has a low viscosity compared to conventional used lubricants, plant extracts are added to generate higher viscosities. In order to avoid tribological influenced damages such as sliding wear and scuffing on the surface of gear flanks, adequate additives are needed. Different combinations of plant extracts and additives were investigated using the scuffing test A/8.3/RT according to DIN ISO 14635-1. The results show a surprisingly high load carrying capacity regarding scuffing. Additionally, two wear tests based on DGMK 377-01 were conducted with one sample fluid. A high risk of sliding wear was detected. Additionally, MTM and SRV measurements were conducted with different polymers to optimize the lubricant. The results of the wear tests help to define operating conditions for a future lubricant based on water and plant extracts. This paper aims to share the results of the performed experimental investigations and discusses the challenges regarding the development of such new lubricants. Full article

Erosion of tidal turbine blades in the marine environment is a major material challenge due to the high thrust and torsional loading at the rotating surfaces, which limits the ability to harness energy from tidal sources. Polymer–matrix composites can exhibit leading-blade edge erosion due to marine flows containing salt and solid particles of sand. Anti-erosion coatings can be used for more ductility at the blade surface, but the discontinuity between the coating and the stiffer composite can be a site of failure. Therefore, it is desirable to have a polymer matrix with a gradient of toughness, with a tougher, more ductile polymer matrix at the blade surface, transitioning gradually to the high stiffness matrix needed to provide high composite mechanical properties. In this study, multiple powder epoxy systems were investigated, and two were selected to manufacture unidirectional glass-fiber-reinforced polymer (UD-GFRP) plates with different epoxy ratios at the surface and interior plies, leading to a toughening gradient within the plate. The gradient plates were then mechanically compared to their standard counterparts. Solid particle erosion testing was carried out at various test conditions and parameters on UD-GFRP specimens in a slurry environment. The experiments performed were based on a model of the UK marine environment for a typical tidal energy farm with respect to the concentration of saltwater and the size of solid particle erodent. The morphologies of the surfaces were examined by SEM. Erosion maps were generated based on the result showing significant differences for materials of different stiffness in such conditions. Full article

Many industrial processes are dependent on the proper application of modern tribological knowledge for the purposes of maintaining equipment integrity and minimizing total energy losses. Consequently, the development of modern lubricants is vital for satisfying growing performance standards and increasingly stringent environmental regulations. Industrial lubricants are regulated based on demanding technical requirements and characteristics, such as high viscosity index, hydraulic stability, corrosion prevention, thermal stability, wide operating temperature ranges, demulsibility, and oxidative stability. Escalating environmental and sustainability concerns have shifted significance towards non-technical criteria for the evaluation of lubricants. Biodegradability and renewability are two influential factors in the discussion regarding the long-term sustainability of future tribological applications. Emphasis is placed on the development of environmentally friendly, non-toxic, and biodegradable lubricants that would minimize industrial pollution associated with oil-related spills and leakages. Bio-based lubricants, manufactured from renewable, organic resources, present themselves as viable alternatives to traditional petroleum-based lubricants. A major section of this review paper will provide a comparative analysis of renewable resource-based lubricants and mineral oil-based lubricants in terms of their chemical properties and respective advantages. Further discussion concerning biolubricants and use of non-edible plant feedstocks will highlight the clear economic and environmental incentives of implementing modern tribological knowledge. This review paper will conclude with the examination of the obstacles that modern day biolubricants must overcome and the future expectations of green tribology. Full article

Deposition of a coating on rough surfaces faces unique challenges due to the complexity of substrate morphology. In the present research, electroless deposition of a Ni-P coating was successfully deposited on diamond particles. Microtomography was conducted to study the deposition mechanisms. It revealed that the coating coverage rate on diamond particles was affected by the synergistic action of the deposition time, substrate morphology, and hypophosphite concentration. The best coverage was achieved in a solution with 0.2 mol/L hypophosphite. Two major morphological features of the coating: nodular and smooth, were influenced by the deposition parameters, coating integrity, and substrate morphology. The failure was seen in fractured and peeled off coatings. It was due to residual stress produced by the coalescing of crystallites during the deposition. This failure mechanism explains the tendency of coating fracture at three morphological features of the substrate. This work is beneficial to semiconductor manufacturing where effective cutting in chip fabrication is essential. Full article

Currently, internal combustion engines contribute to the problem of global warming due to their need to use products derived from fossil resources. To mitigate the above problem, this study proposes the use of coatings on the cylinder bore in order to reduce fuel consumption and polluting emissions. Therefore, in the present study a numerical model is developed in which the tribological behavior, heat fluxes, and leakage of the combustion gases in the chamber are considered to evaluate the influence of the coating. Nickel nanocomposite (NNC) and diamond-like carbon (DLC) coatings are considered in the study. The results demonstrate that the NNC coating produces a 32% reduction in the total friction force of the compression ring. The estimated maximum temperatures for the lubricating oil were 214, 202, and 194 °C for the DLC, steel, and NNC materials. Increasing the temperature in the DLC coating can cause a reduction in the tribological performance of the lubricant. The estimates made show that the implementation of the NNC coating allows a maximum reduction of 5.28 ton of fuel and 39.30 kg of CO emissions, which are based on the global fleet of diesel engines forecast for the year 2025 (corresponding to one hundred and eighty million engines) and a test time of 1800 s. The proposed numerical model allows future analyses to be carried out for other types of materials used as coatings. Additionally, the model can be expanded and adapted to consider other systems that involve friction processes in the engine. Full article

In high speed, high load fluid-film bearings, the laminar-turbulent flow transition can lead to a considerable reduction of the maximum bearing temperatures, due to a homogenization of the fluid-film temperature in radial direction. Since this phenomenon only occurs significantly in large bearings or at very high sliding speeds, means to achieve the effect at lower speeds have been investigated in the past. This paper shows an experimental investigation of this effect and how it can be used for smaller bearings by optimized eddy grooves, machined into the bearing surface. The investigations were carried out on a Miba journal bearing test rig with Ø120 mm shaft diameter at speeds between 50 m/s–110 m/s and at specific bearing loads up to 4.0 MPa. To investigate the potential of this technology, additional temperature probes were installed at the crucial position directly in the sliding surface of an up-to-date tilting pad journal bearing. The results show that the achieved surface temperature reduction with the optimized eddy grooves is significant and represents a considerable enhancement of bearing load capacity. This increase in performance opens new options for the design of bearings and related turbomachinery applications. Full article

When an elastomer approaches or retracts from an adhesive indenter, the elastomer’s surface can suddenly become unstable and reshape itself quasi-discontinuously, e.g., when small-scale asperities jump into or snap out of contact. Such dynamics lead to a hysteresis between approach and retraction. In this study, we quantify numerically and analytically the ensuing unavoidable energy loss for rigid indenters with flat, Hertzian and randomly rough profiles. The range of adhesion turns out to be central, in particular during the rarely modeled approach to contact. For example, negligible traction on approach but quite noticeable adhesion for nominal plane contacts hinges on the use of short-range adhesion. Central attention is paid to the design of cohesive-zone models for the efficient simulation of dynamical processes. Our study includes a Griffith’s type analysis for the energy lost during fracture and regeneration of a flat interface. It reveals that the leading-order corrections of the energy loss are due to the finite-range adhesion scale at best, with the third root of the linear mesh size, while leading-order errors in the pull-off force disappear linearly. Full article

In this study, tribological properties of custom formulated and stabilized nano lubricant are investigated. Spherical CuO nanoparticles are suspended in 20W-50 mineral base lubricant using Oleic Acid (OA) as a surfactant. Three different nano lubricant concentrations with 0.2, 0.5, and 1 wt.% were analyzed through ASTM G-99 pin-on-disc tribometer standardized test under boundary/mixed lubrication regimes. The generated friction and wear analyses confirm a consolidation of tribological properties with a reduction in friction coefficient in the range of 14.59–42.92%, compared with the base lubricant. Analysis of worn surfaces (SEM/EDX) as well as (AFM) was conducted. Combined hypotheses were proposed from the analysis of worn surfaces; these hypotheses suggested that CuO nanoparticles exhibit an integrated effect of two phenomenal lubrication mechanisms. Additionally, dispersion stability evaluation of the suspended nanoparticles was performed through Zeta potential, (FTIR), and sedimentation analyses. Stability results showed that steric stabilization is the dominating effect of the repulsive forces between nanoparticles, surpassing the electrostatic repulsive forces. Full article

Synovial joints are unique biological tribosystems that allow a person to perform a wide range of movements with minimal energy consumption. In recent years, they have been increasingly called “smart friction units” due to their ability to self-repair and adapt to changing operating conditions. However, in reality, the elements of the internal structure of the joints under the influence of many factors can degrade rather quickly, leading to serious disease such as osteoarthritis. According to the World Health Organization, osteoarthritis is already one of the 10 most disabling diseases in developed countries. In this regard, at present, fundamental research on synovial joints remains highly relevant. Despite the fact that the synovial joints have already been studied fully, many issues related to their operating, prevention, development of pathology, diagnosis and treatment require more detailed consideration. In this article, we discuss the urgent problems that need to be solved for the development of new pharmacological agents, biomaterials, scaffolds, implants and rehabilitation devices for the prevention, rehabilitation and improvement of the treatment effectiveness of synovial joints at various stages of osteoarthritis. Full article

Because of the influential role of consistency in selecting a grease for a given application, accurate and meaningful methodologies for its measurements are vitally important. A new method, recently introduced, uses a rheometer to compress a grease sample to evaluate a relative consistency between a fresh and degraded grease; however, the results of this approach compared to a standard penetrometer and other methods of assessing consistency have not been studied. This paper takes a closer look at the relevant parameters involved in the rheometer penetration test and establishes a recommended procedure for its use. The consistency of various greases is then tested using this method and compared to results obtained from yield stress, crossover stress, and cone penetration tests. The results indicate that rheometer penetration may be used to assess the change in consistency for a given grease but should not be used to compare different greases. For this purpose, the crossover stress method is recommended, which is shown to correlate very well with cone penetration while using a simple procedure and allowing the use of a substantially smaller sample. A strong power law correlation between crossover stress and cone penetration was found for all greases tested and is presented in Figure 12. Full article

The fretting corrosion behaviours of Al₂O₃ ceramic/Ti6Al4V alloy, 316 L stainless/Ti6Al4V alloy, and CoCrMo alloy/Ti6Al4V alloy pairs were studied in an in-house developed fretting-corrosion tester. The fretting behaviours were characterized by the F_t-D-N and F_t/F_n curves. The morphology of the worn surface was analyzed by energy dispersive X-ray spectrometry (EDX), a scanning electron microscope (SEM), and a white light interferometer (WLI). The fretting regimes were found to vary from slip regime (SR) to mixed fretting regime (MFR), with an increase in loads for the Al₂O₃/Ti6Al4V and 316 L/Ti6Al4V pairs, while for the CoCrMo/Ti6Al4V pair the fretting always remained in SR. The damage mechanism of the Al₂O₃/Ti6Al4V pair was mainly abrasive wear and corrosive wear, while for the 316 L/Ti6Al4V pair and CoCrMo/Ti6Al4V pair, the wear mechanism was mainly adhesive wear and corrosive wear with slight abrasive wear. The electrochemical impedance spectrum results show that the material transfer layer formed on the surface of the material can protect the material from corrosion for the 316 L/Ti6Al4V and CoCrMo/Ti6Al4V pairs. Full article

Grease is highly susceptible to degradation due to regular usage and the severity of the operating conditions. Degradation can negatively impact the performance of grease-lubricated machinery, demanding frequent maintenance to avoid premature failure of machine elements. Quantification of grease degradation has proven to be a formidable task, for which no accepted standards are currently available. In this paper, we extend the results of a novel approach developed recently for the evaluation of the water-resistant property in grease to quantify degradation. The methodology is based on measurements of the contact angle of a water droplet on the surface of a sample of grease. We report the results of extensive tests performed on different grades of lithium complex greases to evaluate the variation of contact angle values with the composition of grease. The measurements were compared with penetrometer readings to quantify a relationship between the grease consistency and contact angle. Detailed study results are also presented on three types of greases sheared in a grease worker for a different number of strokes: contact angle and the yield stress values were measured and compared. Finally, the tribological characteristics were determined for two greases that exhibited a low or high change in their contact angles. Full article

Several approaches have been developed to measure instantaneous friction between the piston assembly and cylinder in internal combustion (IC) engines, such as floating-liner, reciprocating liner, instantaneous mean effective pressure (IMEP), fixed sleeve, and (P-ω) method and tribological bench tests. However, the “floating-liner method” and the “(IMEP) method” are the most common methods used to measure instantaneous friction between the piston assembly and IC engines. This paper critically evaluates different approaches to the design of the “floating-liner”. The paper begins by discussing piston assembly frictional losses and their significance and then discuss the development of instantaneous piston-friction measurements. After that, it reviews the main design challenges in the floating-liner approach. “Methods of cylinder sealing” and “force balancing methods” are also reviewed. Design challenges associated with firing operation were presented. Floating-liner designs were classified into different categories with a detailed presentation of the features of each. The paper ends by presenting a range of broad recommendations for further work which would benefit future designs. Full article