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Life Cycle Tribology 109

D. Dowson et al. (Editors)


9 2005 Elsevier B.V. All fights reserved

Electrostatic monitoring of the effects of carbon black on lubricated steel/steel sliding


contacts

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

effects of organic and inorganic acids originating


1. INTRODUCTION from combustion gases and oil oxidation. In
extreme cases deposits can clog oil filtration systems
1.1 Oil chemistry resulting in a lack of oil flow and subsequent engine
Lubrication demands for current sophisticated failure [4].
diesel engines would not be met without the use of Detergents and dispersants are, generally, long
tailored packages of chemical additives. Harmful chain hydrocarbons with polar ends. Detergents are
by-products of the combustion process typically alkali or alkaline earth metal salts of oil
(incompletely combusted fuel, polynuclear aromatic soluble organic acids, for example, alkyl benzene
hydrocarbons, organic acids, soot, nitrates, sulphonic acids or alkyl phenols; detergents may be
sulphates, and water) contaminate the oil over time. overbased such that a reserve of basic compounds is
The incorporation of dispersants, detergents, dispersed in the engine oil. Dispersants utilize
inhibitors for wear and oxidation, and other oxygen and/or nitrogen for polarity; typical
additives is essential. Dispersants are used to dispersants are the imides of polyisobutenyl succinic
prevent build up of harmful carbon and sludge anhydrides and ethylene polyamines [4]. In engine
deposits, which can lead to oil thickening thereby oils, additives disperse, neutralize, and generally
affecting viscosity stability and flow properties. protect engine components from harmful
Detergents are necessary to mediate the corrosive contaminants.
110

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.

Electrostatic charge monitoring has been shown


to monitor wear generated by:
9 Gears
9 TE/77 reciprocating wear rig
9 Conventional bearings
9 Hybrid bearings
9 Dry and lubricated sliding contacts

2. EXPERIMENTAL PROCEDURE

2.1 Pin-on-disc tribometer (POD) and on-line


Figure 1 Schematic of the electrostatic charge condition monitoring system
sensing system Figure 2 shows a schematic of the pin-on-disc
Electrostatic monitoring has also been applied to wear test rig with the associated instrumentation. As
oil lubricated contacts. The primary advantage of well as the electrostatic probe, which was located 90
using the electrostatic sensing technique compared degrees away from the pin/disc contact and 0.5 mm
with conventional debris monitoring technologies is above the wear track, a strain gauge was installed to
that it is sensitive to most material types including monitor the friction force, an LVDT to monitor the
ferrous, metallic, and non-metallic such as ceramics. total vertical linear wear, an infrared thermometer to
Importantly it is a non-contact method. Figure 1 is a monitor the surface temperature on the disc (about
schematic of the electrostatic charge sensing system, 10 mm away from the contact point), and a
demonstrating the principle of its operation. tachometer to monitor the rotating speed.
112

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

Density [kg/m 3] 965 8571856 856 857 [ 842 854

Conductivity
1210 I 8320 I 24000 I 7~ 14070 I 7."
[pS/m]
.

Table 2 Summary o f Oils tested (* - denotes Z D D P present).


polymeric succinimide has about 10 polar
2.2.1 Oil chemistry heads per molecule, and the bis-succinimide
Oil blends were prepared from baseline has one polar head per molecule [28-30].
formulations that contained 7.3 percent VII - VII: An ethylene/propylene copolymer.
(Viscosity Index Improver) concentrate, and 50 mM - ZDDP: A primary Zinc dithiophosphate.
Ca (from detergent). Dispersants were treated on an - Carbon Black: The carbon black used as
equal weight basis, 8.0 percent. Oils with ZDDP a surrogate for diesel engine soot was Raven
were blended to 0.1% phosphorus. 1040 supplied by Columbian Chemicals
9 Description of compounds in oil blends: Company, Marietta, GA, USA. Raven 1040
- Detergent: An overbased sulphurized calcium has the following properties [31 ]:
phenate detergent. The detergent is
9 Particle Size" 28nm
characterized by a total base number of 250
9 Nitrogen Surface Area: 95m2/g
mgKOH/g, and 9.25% Calcium.
9 Cetyltrimethylammonium Bromide
- Dispersant 1: A commercially available post- Surface Area: 100m2/g
treated conventional bis-succinimide made
9 Dibutylphthalate Oil Absorption:
from polyisobutene having a number average
100cc/100g
molecular weight of 2300 Daltons. It is 9 Density: 192 kg/m 3
characterized by 1.0% nitrogen. The
9 p H : 2.8
theoretical molar mass is about 5600 Daltons
9 Percent Volatile: 3.0
with one polar head per molecule [27,28].
- Dispersant 2: A polymeric succinimide 2.2.2 Oil sample Preparation
dispersant. It is characterized by 1.2%
nitrogen. It is made from an alpha Oil samples 8, 9, 10, and 11, and carbon black
olefin/maleic anhydride copolymer having a were mixed using a rotor stator type high shear
degree of oligomerization of about 10, a mixer model T25 Basic Dispenser w/S25N-18G
polyisobutenyl succinic anhydride having a manufactured by IKA Laboratory Analytical and
number average molecular weight of about Processing Equipment. Oil and carbon black were
2300, and an ethylene polyamine. It is a mixed for one minute, and then the oil was degassed
mixture, theoretically of one mole of in a vacuum oven for 15 minutes at about 55~ Oil
polymeric succinimide, Mn~35000, and four samples 3 & 11 were prepared by mixing 2% Raven
moles of bis-succinimide, Mn=5600. The powder with Oil 2 & 7 respectively. The mixtures
114

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.

Charge / pC i Coefficient Temperature / ~ SWR / mm3/Nm


Oil LVDT / mm/min Conductivity
No. rms stdev of Friction Steady AT Pin Disc / pS m ~
i
State
2.78x 10 -Is 4 . 1 2 x 10 "i8 1.26 x 10 .4 1.2
1 10.016 0.009 i
0.063 37.3 13
2 0.015 0.006 0.068 29.7 7 5 . 9 5 x 1 0 "i9 4 . 8 0 x 10 "18 1.14 x 10 .5 6590
u i

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

4 0.023 0.010 ! 0.088 43.4 21 7 . 6 3 x 1 0 "i9 7 . 2 3 x 1 0 "!8 3.62 x 10 .6 8320


|l

5 I0.017 0.007 0.070 29.9 11 6 . 0 3 x 1 0 "i9 5.29x 10 "18 1.22 x 10 .4 15840


|| |

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

8 0.017 0.007! 0.071 37.8 15 5.16x 10 "19 2 . 6 7 x 10 "18 3.05 x 10 .5 1170


i| J

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
||

10 0.026 0.008 0.067 40.8 21 5 . 9 4 x 1 0 "j9 8 . 0 0 x 1 0 "!8 1.53 x 10 .4 14070


11' 0.016 0.006 0.083 39.8 18 2.53 x 10 "17 n/a 1.66 • 10 -4 7380

Table 3 Results (*- denotes ZDDP present).


115

conductivity for oil 4, which contains only VII and


3.1 Effect of Oil Chemistry and Carbon Black detergent. The reasons for this are not well
Contamination on Conductivity understood at this time, but the well-known
The preliminary results of the effect that oil detergent/dispersant interaction [34] may play a role.
chemistry and carbon black contamination have on Third, addition of ZDDP to both oils 6 and 10,
conductivity are summarized in Figure 3. appears to lower the conductivity by a considerable
Conductivity clearly varies with oil chemistry and at amount. The well-known dispersant/ZDDP
this point several generalizations can be made. First, interaction [34] may be playing an important role
the conductivity in the presence of 2% carbon black here.
appears to be lower in most cases than the
conductivity in the absence of 2% carbon black. 3.2 Effect of Oil Chemistry and Carbon Black
This may be due to the well-known ability of carbon Contamination on Surface Charge
black to adsorb polar compounds that may be The effect of oil chemistry and carbon black
present as contaminants in either VII, detergents, or contamination on surface charge, Qrms, is
dispersants. This effect needs to be explored in summarized in Figure 4. At this point there are only
more detail. Second, it appears that the highest slight differences in the surface charge as the oil
conductivity arises when VII, detergent, and additive chemistry changes. These subtle changes
dispersant are all combined together in the base oil. are not well understood and are being investigated
The conductivities for oils 5 and 6, which contain further.
VII, detergent, and dispersant 1 and dispersant 2
respectively, are considerably greater than the

Figure 3 Effect of oil chemistry and carbon black contamination on conductivity


116

Figure 4 Effect of oil chemistry and carbon black contamination on surface charge

Figure 5 Effect of oil chemistry and carbon black contamination on temperature


117

Figure 6 Effect o f oil chemistry and carbon black contamination on wear


Conceivably, this temperature increase was due
3.3 Effect of Oil Chemistry and Carbon Black to an increase in abrasive wear (mechanical action)
Contamination on Friction and or viscous heating (due to agglomeration of carbon
Temperature Increase black). Again this requires further investigation.
Figure 5 shows the change in temperature
observed during these experiments. Detergent and 3.4 Effect of Oil Chemistry and Carbon Black
ZDDP form rough boundary films [35,36] and, in Contamination on Wear
the absence of carbon black, higher friction and a In Figure 6, the addition of carbon black resulted
greater increase in temperature was observed when in minor to major increases in wear rate (see Oils 2
these films were likely to form (Oils 4 and 7). vs. 3; 5 vs. 9; 6 vs. 10; and 7 vs. ll). This is
Succinimide dispersants are known to interfere with consistent with the known abrasive nature of carbon
the formation of boundary films [34&37]. Neither black [8]. For Oil 7, the wear rate was very low due
an increase in the coefficient of friction nor an to the addition of ZDDP, a known wear inhibitor.
increase in temperature was observed when either Comparison of the wear rates of Oil 4 to Oils 5 and
dispersant was added to Oil 4 (relative to Oil 2) as 6 show that the addition of dispersant 1 or 2 to Oil 4
shown in Figure 5, and Table 3. gave higher wear rates. This is in agreement with the
Generally, oils contaminated with carbon black observation in electrical contact resistance (ECR)
exhibited a large temperature increase; however, the experiments that dispersants can slow down the rate
coefficient of friction was not changed. of anti-wear film formation [37].
118

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

except those contain ZDDP. This


3.5 Post-test disc surface profilometry analysis suggests an increase in abrasive wear
Figure 7 shows the 3-D images of the wear (mechanical action) or viscous heating
tracks on the disc after testing with oils 1,2,5,9,10 & due to agglomeration of carbon black.
7. Table 4 gives more details about the wear track Carbon black contamination results in
width and depth. higher wear rate for all oil formulations
Oil Wear track Wear track including those that contain ZDDP. This
Types depth (~m) infers that the primary ZDDP does not
width (~tm)
control wear in the presence of 2%
260 7.6
carbon black contamination.
2 340 6.0
Addition of carbon black did not appear
5 310 5.6
to significantly influence the wear
9 250 4.0
mechanism with only slight signs of
10 220 5.6 increased abrasion or polishing.
7 190 3.6
Table 4 Disc wear track widths and depths on 3.7 Future Work
tests with selected oils. The experiments described in this paper
comprise the preliminary evaluation of test
Profilometric studies showed that Oil 7 not only
conditions for a more thorough study of the
gave the lowest wear, but the surfaces appeared
appreciably smoother than the others. This effect is sensitivities between charge and wear, and the
effects of additive chemistry and contamination. The
reminiscent of the study by Snidle et al [38], who
results described in this paper will be used to design
used ZDDP in base oil and observed a marked
a matrix using factorial techniques. Factors under
improvement of the surface topography in a steel-
on-steel tribocouple just prior to scuffing. consideration are tribo-couple type, oil aging by
contamination or oxidation, and variation of additive
Oil 1 has a unique wear scar geometry being 'v'
shaped while others are 'u' shaped with type.
polished/light-abraded tracks evidenced by
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