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R J K Wood a*, P Ramkumar a, L Wang a, T J Harveya, K Nelson b, E.S. Yamaguchi b, J.J. Harrison b, H E G
Powrie c and N Otin a
a Surface Engineering and Tribology Group, School of Engineering Sciences, University of Southampton,
Highfield, Southampton. SO17 1BJ, UK.
b Chevron Oronite Company, LLC, Additive Synthesis and Processing Unit, 100 Chevron Way, P.O. Box
1627, Richmond, CA 94802-0627, USA.
c Smiths Aerospace, Electronic Systems-Southampton, School Lane, Chandler's Ford, Hampshire SO53
4YG, UK.
The aim of this work is to understand better the relationship between the wear of sliding tribo-contacts and
soot contamination in diesel lubricants, as modelled by the presence of carbon black. The work examined
sensitivities between charge and wear induced by carbon black-contaminated lubricants. Previous research,
using a pin-on-disc (POD) tribometer [1-3], has shown correlations between wear, friction and temperature with
electrostatic charge detected by sensors mounted a distance from the contact but focused on the disc wear track.
These correlations were found for both steel/steel and steel/Si3N4 contacts lubricated by uncontaminated base
oils and commercial aviation oils. The present test programme has been carried out on a pin-on-disc tribometer
which was instrumented with Linear Variable Differential Transformer (LVDT), temperature and friction
transducers, as well as an electrostatic wear site sensor. The test conditions of 5m/s sliding velocity and a
contact stress of 2.05 GPa were chosen to match test conditions used previously.
Results from a preliminary test programme which varied the detergents, dispersants and carbon black in
lubricants are discussed. Comparisons between the wear rates, friction, disc surface temperature, oil
conductivity, oil chemistry, and electrostatic charge are presented for the various Group 1 oil formulations.
These studies suggest designs for a systematic matrix to understand how charged additive and/or contaminant
species influence wear and performance over time. Analysis using optical spectroscopy and 3-D profilometry of
the worn surfaces of the pin and disc were used to identify the wear mechanisms.
Key words: Soot, additives, lubrication, wear, bearing steel, electrostatic sensing
Zinc dialkyldithiophosphates (ZDDPs) have been components as well as other oil properties including
the additive of choice for the control of wear and phosphorus level, dispersant level and sulphonate
oxidation for over 50 years. They were originally substrate level. The results showed that the oil's
developed as antioxidants but later were anti-wear performance was reduced due to the
implemented for their anti-wear properties. The interaction between soot and oil additives. It was
anti-wear agent interacts with the metallic surface to also found that the phosphorus level of the oil plays
form relatively thick boundary lubrication films. a dominant role on wear performance; the effect of
These films are complex multi-layer structures dispersant level was not very significant, though on
whose composition is dependent on contact average, higher dispersant levels decreased wear.
conditions and oil formulation [5]. It has been Carbon black can be manufactured to have
reported that the composition of these films on similar characteristics as soot, but the highly
ferrous surfaces consists of an iron oxide/sulphide controlled conditions produces carbon black of
layer close to the surface with a thick middle layer of greater uniformity and without any impurities [11].
amorphous glass polyphosphate containing digested Various types of carbon blacks have been examined
iron with a hydrocarbon rich outer layer [6,7]. and compared with different forms of engine soot
ZDDP films are susceptible to abrasive wear, as [ 13], and it was found that most commercial furnace
shown by Ryason et al [8] in a model study and channel carbon blacks, e.g. Vulcan XC72R,
involving carbon black as a surrogate for soot. Soot appear to resemble soot from diesel engines.
is a major contaminant produced by diesel engines; Ryason et al [8] studied the polishing wear of diesel
measures employed in recent years to reduce the engines by soot using Raven 1040, which has a
level of nitrous oxide emissions, such as retarded primary particle diameter of about 0.030-0.040 ~tm,
fuel injection timing and exhaust gas recirculation while typical soot particles have diameters ranging
(EGR), give rise to high levels of soot. High levels from 0.01 ktm to 0.8 ~tm [12]. Their results showed
of soot produce significant challenges to the that the carbon black behaved like an abrasive which
dispersants, detergents, and wear inhibitors. caused polishing wear on the steel surfaces. Rounds
Furthermore, there is a need to reduce the amount of et al [14,15] explored the effect of lubricant
sulphur and phosphorus in the engine oil, since additives on the pro-wear properties of diesel engine
catalysts for the reduction of exhaust emissions are soot, and synthetic soots formed from carbon black,
sensitive to these elements [9,10]. Mindful of these and synthetic soot prepared from soot collected from
constraints, this paper describes experiments aimed diesel engine exhaust. They found that carbon black
at understanding the relationship between wear in could be made to behave more like diesel engine
sliding contacts, oil chemistry and soot in model soot when it was treated with the oil at combustion
diesel lubricants. chamber temperatures followed by a second
treatment at oil sump temperatures; diesel exhaust
1.2 Carbon black/soot soot was made to behave more like diesel engine
Although diesel engines have become more and soot when treated with the oil at oil sump
more popular due to their higher fuel efficiency and temperatures. The pro-wear characteristics of the
lower maintenance costs, 'soot' particles formed in carbon black and exhaust soot, used in these
diesel engines due to incomplete combustion have experiments, was increased by the treatment.
led to increased oil contamination and wear of
engine parts. Soot is primarily made from carbon 1.3 Electrostatic sensing technology
which has formed aromatic molecular networks; Tribocharging is a well-known phenomenon
soot particles form highly extended networks [11]. relating to charge transfer when two surfaces come
Wear of engine components could be due to into contact. This phenomenon can be broadly
chemical reactions taking place on the surface (such explained by considering the contact between two
as corrosion) or abrasive action on the material or different materials. Charges transfer from one
anti-wear film by soot particles. Over the last surface to the other in order to bring the contacting
twenty years, much attention has been given to materials into thermodynamic equilibrium
modelling soot formation and its evolution (coincident Fermi energies). If these surfaces are
thereai~er. Gautam et al [ 12] examined the effects of quickly separated and the two surfaces remain
soot-contaminated engine oil on wear of engine isolated from earth, they will retain a net charge.
111
Thus, by making and breaking contacts between The basic difference between monitoring debris
different materials, net charging occurs. in the jet engine gas path and in oil is that the overall
The electrostatic sensor is sensitive to charge charge levels in an oil lubricated contact are also
which has originated from tribological action, as influenced by the chemistry, impurity concentration,
well as being sensitive to charge generated by other conductivity and temperature of the oil as well as
mechanisms [16-22]. The technology is based on surface charging due to wear induced phase
the premise that a change in the charge levels is a transformation, additive film and oxide film
result of changes in the condition of the dynamic formation and removal, cracking etc. For charged
system. This technology was originally developed debris in oil and for the surface charge on worn
for detection of debris in the gas path of jet engines surfaces, it has been found that an increase in the oil
and gas turbines by monitoring the electrostatic conductivity will cause a decrease in the magnitude
charge associated with the debris present in the gas of the charge detected [25]. This is explained by
path. Changes in the charge level are related to the charge leakage from the debris to the oil which,
presence of increased amounts of debris and hence amongst other factors, will be a time-dependent
the onset of gas path component deterioration function. This will act in opposition to any charging
[23,24]. as a result of tribological action. Also, conductivity
is directly influenced by impurity levels within the
oil. The presence of additives and other chemicals
in the oil also affects the surface charging due to
their reaction with active wear surfaces. Thus, the
charge detected by the electrostatic sensing system
will be affected by the following parameters/factors:
9 Contact and debris materials
(conductive/non-conductive);
9 Oil properties (base oil group, additive
chemistry etc), quality and temperature;
9 Earth plane/sensor proximities.
2. EXPERIMENTAL PROCEDURE
Figure 2 (a) Schematic diagram of the POD test set-up (b) Position of electrostatic sensor
An on-line data acquisition system was used to additional running-in at the new load. After the
collect the charge, friction, linear wear, and surface maximum load of 30 N was applied, tests were run
temperature signals in real-time. Suitable signal for one hour. The initial ~. (the ratio of minimum oil
conditioning was applied to the sensors. A DAT film thickness to the roughness of the surfaces) was
recorder was also used to store the raw data as a 0.3, which means that all tests were initially in the
back up. boundary lubrication regime according to the
Stribeck curve. The test pins were ultrasonically
2.2 Test conditions and procedure cleaned in a mixture of acetone and ethyl acetate for
All tests were carried out under ambient 15 minutes before and after testing. The disc
conditions (temperature = 18-28~ relative surfaces were also cleaned with the same solvent
humidity = 40-70%) at a sliding speed of 5 m/s and using cotton wool pins before and alter tests.
load of 30 N (2.05 GPa initial contact pressure).
These are mildly accelerated conditions compared Pin Disc
with typical valve-train entrainment velocities and
Material Steel En31
contact pressure. Hertzian contact stress in the range
0.95-1.1% C, 0.1-0.35%
of 1.7-2.07 GPa has been reported for low emission
Composition Si, 0.4-0.7% Mn, 1.2-1.6
diesel engines [26]. Tests were carried out on the
fully instrumented pin-on-disc tribometer with an Cr, Remainder Fe
En31 steel ball loaded against an En31 steel disc, Hardness (Hv3o) 640 220
lubricated by various model automotive diesel oils. Elastic Modulus, E [GPa] 210 210
The amount of wear and the wear mechanisms were Poisson's ratio, n 0.3
quantified and determined retrospectively.
The tests started with the disc rotating but with Density, p [kg/m3] 7.80x 103
no load or contact for 2 minutes in order to record O60mm x
Dimensions O6mm
background signals before the oil was sprayed onto 10mm
the disc (about 20 ml/hour). After the disc surface Roughness, Rq [~tm] 0.09 1.14
was fully lubricated (another 5 minutes), an initial
running-in load of 10 N was applied for 5 minutes. Table 1 Pin and Disc Material Properties
The load was then increased in regular increments, The properties of the pin/disc materials and the
with 5 minutes between each increase to allow
oils are listed in Table 1 and Table 2 respectively.
113
Oils 8 9
API Group 1
Viscosity Index r r r r r
Improver
r r r r
Detergent
Dispersant 1 r r
Dispersant 2 r
Carbon Black r r
Conductivity
1210 I 8320 I 24000 I 7~ 14070 I 7."
[pS/m]
.
were stirred for 10 minutes followed by 60 minutes Where VL is the volume loss of the disc or pin, F
in an ultrasonic bath at 30~ Just prior to testing on is the load and SD is the sliding distance.
the POD tribometer, all samples were ultrasonically On-line signals from the sensors were processed
shaken for 20 minutes. to give real-time results, including both rms and
standard deviation (stdev) charge levels (Q~ms& Qsd,
2.2.3 Oil conductivity measurement pC), the slope of LVDT signal which give the linear
The conductivity measurements were performed wear rate of pin & disc (mm/min) and the mean
prior to wear testing with a Wolfson Electrostatic coefficient of friction (COF) under steady state
liquid conductivity meter, made at the University of conditions, i.e. when temperature and friction levels
Southampton. Details of this equipment are shown are relatively stable. The temperature rise (~ over
in [32,33]. the test duration was also calculated (AT) as well as
the mean temperature under steady state conditions
2.3 Post-test analysis and on-line signal (Tss).
processing
The pin and disc volume losses were obtained by
post-test analysis of the pin wear scars and disc wear 3. R E S U L T S AND D I S C U S S I O N
tracks measured using 3-D laser profilometry. The data gathered with the on-line
Average specific wear rates (SWR) were then instrumentation including, surface charge level,
calculated using equation (1): coefficient of friction, steady state temperature and
temperature change (AT), and the wear measurement
by LVDT, are shown in Table 3. The specific wear
VL (mm 3) rate on the pin and disc, calculated from post-test
SWR = (1)
F (N) x SD (m) analysis and the conductivity of the oil, taken prior
to testing on the POD tribometer, are also given.
3 0.031 0.015 0.068 45.7 20 4.53 x 10 "19 3.78 x 10 "18 2.14 x 10 -5 1210
I! I i i
6 0.016 0.007 0.068 29.5 13.5 1.03 x 10 "18 8.95x 10 "18 9.42 x 10 "s 24000
|, |
7* 0.016 0 . 0 0 7 i 0.120 47.0 21.5 2.38x 10 "18 1.97x 10 "i8 4.23 x 10 "6 6990
i i
9 0.020 0.009 0.067 46.2 20 9.29x 10 "19 8.51 x 10 "18 1.56 x 10 "4 7780
||
Figure 4 Effect of oil chemistry and carbon black contamination on surface charge
Figure 7 3D wear track images for oils:(a) Oil 1, (b) Oil 2, (c) Oil 5, (d) Oil 9, (e) Oil 10, and 09 Oil 7
119
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