Search Results (35)

As part of a publicly funded cooperation project, novel high-performance lubricants (oils, greases, assembly pastes) based on ionic liquids and with the addition of specific micro- or nanoparticles are to be developed, which are adapted in their formulation for use in applications where their negligible vapor pressure plays an important role. These lubricants are urgently needed for applications in cleanrooms and high vacuum (e.g., pharmaceuticals, aerospace, chip manufacturing), especially when the frequently used perfluoropolyethers (PFPE) are no longer available due to a potential restriction of per- and polyfluoroalkyl substances (PFAS) due to European chemical legislation. Until now, there has been a lack of suitable laboratory testing technology to develop such innovative lubricants for extreme niche applications economically. There is a large gap in the tribological test chain between model testing, for example in the so-called spiral orbit tribometer (SOT) or ball-on-disk test in a high-frequency, linear-oscillation test machine (SRV-Tribometer from German “Schwing-Reib-Verschleiß-Tribometer”), and overall component testing at major space agencies (ESA—European Space Agency, NASA—National Aeronautics and Space Administration) or their service providers like the European Space Tribology Laboratory (ESTL) in Manchester. A further aim of the project was therefore to develop an application-orientated and economical testing methodology and testing technology for the scientifically precise evaluation and verifiability of the effect of ionic liquids on tribological systems in cleanrooms and under high vacuum conditions. The newly developed test rig is the focus of this publication. It forms the basis for all further investigations. Full article

The relationship between the structure characteristics and performances of coal-based hydrogenation isomeric (CTL) base oil and metallocene-catalyzed coal-based poly-alpha-olefin (mPAO) base oil is clarified in this paper. CTL and mPAO were compared with typical petroleum-based and natural gas-based commercial API III and IV base oils. Pressurized differential scanning calorimetry (PDSC), the rotary bomb oxidation test (RBOT), and a four-ball friction tester were used to evaluate the oxidation stability and lubrication performance of base oils under different working conditions. The sensitivity of different base oils to typical antioxidants and extreme-pressure antiwear agents was compared. In particular, the composition and structure of CTL base oil are clearly different from GTL and mineral base oil. The coal-based CTL and mPAO base oils exhibit commendable viscosity–temperature properties, coupled with low-temperature fluidity, fire safety, and minimal evaporation loss. The lubricating properties, oxidation stability, and sensitivity to extreme-pressure antiwear agents of CTL are close to those of similar base oils. However, the sensitivity of CTL to typical antioxidants is relatively poor. In addition, compared with commercial PAO base oil, mPAO has a lower isomerization degree and fewer isomerization types. The oxidation stability and sensitivity to typical antioxidants of mPAO base oil are comparable with those of commercial PAO base oil, while its lubrication performance and sensitivity to typical extreme-pressure antiwear agents are significantly better than those of commercial PAO base oil. Full article

In this study, layered double hydroxide (LDH) and molybdenum disulfide (MoS₂) were used as additives to prepare lubricants. The morphology and particle distribution of the LDH and MoS₂ were characterized using a scanning electron microscope and a laser particle size analyzer, respectively. Thermogravimetric analysis was used to compare the performance of the lubricants at high temperature. The extreme pressure and wear resistance performance of the lubricants were tested using a four-ball machine and a fretting-wear machine. Then, the lubricants were applied in a bolt fastener. The loosening torque and surface wear condition at high temperature were compared. By adding LDH and MoS₂ to the lubricants, the extreme pressure and wear resistance performance and anti-seize performance at high temperature were improved significantly. The LDH showed better anti-seize performance than the MoS₂ because of its strong and stable structure at high temperature. The MoS₂ showed better anti-wear performance under a high load because of its soft layered structure. The MoS₂ with a larger particle size showed better extreme pressure performance under a high load. The LDH and MoS₂ played a synergistic effect under the conditions of high temperature and high load. Full article

A new kind of modified emulsified bitumen used to plug a microcrack was studied. The sizes of high-temperature emulsified bitumen were fit for the sizes of the microcrack, which were approved by the scanning electron microscope and laser particle size analyzer. Some tests have been designed to demonstrate that the polymer could be used to promote the softening point of modified asphalt, and the high-temperature emulsified bitumen has also shown an excellent performance in terms of static filtration, the viscous coefficient, and extreme pressure lubrication, as well as to inhibit ting shale expansion. The permeability recovery could reach 88.26%, which meets the specification requirements. The mud cake, which was formed by high-temperature emulsified bitumen as an additive, was thin, tough, and dense, which was proved by the scanning electron microscope. The process used to obtain this additive was simple, and the performance of the plugging microfracture was excellent, so this kind of plugging agent could have a better application future. Full article

To enhance the performance and reduce the amount of ester-based lubricants used in weak gel drilling fluids, a shear dynamics simulation under extreme pressure conditions was employed to refine the formulation of the base oil and pressure additives. The simulation results were validated using fatty acid methyl, ethyl, and butyl esters. Fatty acid methyl ester demonstrated the lowest temperature increase and the highest load-bearing capacity post-shear. The four-ball friction test revealed that methyl oleate had a coefficient of friction of 0.0018, approximately a third of that for butyl oleate, confirming the simulation’s accuracy. By using methyl oleate as the base oil and oleamide as the pressure-resistant component, the optimal shear stress was achieved with a 10% addition of oleamide. A lubricant composed of 90% methyl oleate and 10% oleamide was tested and showed a coefficient of friction of 0.03 when 0.5% was added to bentonite slurry, indicating a strong lubricating film. Adding 1% of this lubricant to a low gel drilling fluid system did not affect its rheological properties, and the gel structure remained stable after seven days of aging. Field tests at the Fu86-3 well in the Jiangsu Oilfield of Sinopec confirmed that adding 1% of the ester-based lubricant to the drilling fluid significantly improved drilling efficiency, reduced drag by an average of 33%, and increased the drilling rate to 22.12 m/h. This innovation effectively prevents drilling complications and successfully achieves the objectives of enhancing efficiency. Full article

The performance and durability of high-pressure fuel systems in combustion engines are critical for consistent operation under extreme conditions. High-pressure fuel systems are traditionally lubricated with fuel that is compressed and delivered to the combustion chamber. However, lubrication with fuel presents significant challenges in these systems when used with low-viscosity fuels, leading to increased wear rates, especially in reciprocating contacts. This study delved into the tribological performance of steels of varying alloy content (annealed and hardened variants of AISI-52100, CF2, and D2) against alumina and hard 52100 counterbody materials in ethanol and decane environments. Friction and wear behaviors were evaluated, highlighting the influence of material interactions and environmental factors. Elastohydrodynamic lubrication analysis of the tested systems indicated that ethanol and decane form lubricating films of nanometer-scale thickness, confirming the boundary lubrication regimes of the performed tests. In summary, the tribological behavior trends were similar for alumina and 52100 counterbodies. Even though soft 52100 steel demonstrated low friction, its wear was the largest for both tested environments and counterface materials. Among all the tested materials, hard D2 experienced the lowest wear. 52100 and D2 steels showed opposite friction change behavior when comparing hard and soft samples, with lower friction observed for softer 52100 steel and harder D2 steel. Meanwhile, the wear was lower for harder candidates than for softer ones independent of the environment and counterbody material. Raman spectroscopy analysis of the formed wear tracks indicated the formation of carbon films with larger intensities of characteristic carbon peaks observed for more wear-resistant materials. These results suggest the synergistic effect of hardness and tribochemical activity in reducing the wear of materials. Full article

Recent green manufacturing demands have boosted the development of new biodegradable lubricants to replace petroleum-based lubricants. In this regard, water-based lubricants have been at the vanguard of recent research for a wide range of industrial applications, including metalworking fluids (MWFs). In this work, we present an experimental investigation on the performance of novel green MWFs based on aqueous nopal mucilage solutions. For this, fully biodegradable solutions with different mucilage concentrations (2.29, 4.58, and 6.85 mg/mL) were evaluated in terms of rheological, tribological, thermal stability, and turning (minimum quantity lubrication) performance and compared to a commercial semisynthetic oil-based MWF (Cimstar 60). Mucilage solutions exhibited viscoelastic shear-thinning behavior, which was enhanced along with mucilage concentration. The solution with the highest mucilage content studied resulted in the lowest wear, friction, and temperature in comparison to the other solutions and neat water in extreme pressure four-ball tests and a similar level of lubricity as compared to the commercial MWF in cutting tests. This performance is associated with the enhanced viscosity and elasticity of the solution, as well as the contents of lipids with fatty acids in the mucilage. Overall, the present results reveal the relevance of the viscoelastic behavior of the lubricant, elasticity in particular, in lubrication processes and point to nopal mucilage as an effective green additive to produce innocuous MWFs. Full article

Water-lubricated bearings are widely used in marine equipment, and the lubricating water often contains hard particles. Once these particles enter the gap between the bearing and the shaft, they can scratch the smooth surfaces of the shaft and bearing, influencing the working performance of the bearing system. To investigate the effect of scratch parameters on tribological performance, this paper conducts multiple block-on-ring experiments and constructs a mixed-lubrication model under water-lubrication conditions. The results show that among the three commonly used bearing materials, the tribological performance of graphite block is the most sensitive to scratches on the test ring surface. Under the condition of one scratch (N = 1), the loading area of water film pressure is divided into two separate zones (a trapezoidal pressure zone and an extremely low-pressure zone). In addition, the variation of maximum water film pressure is determined by the positive effect (hydrodynamic pressure effect of fluid) and negative effect (“piercing effect” of the asperities). Compared with the scratch depth and scratch location, the scratch width has the most significant effect on the tribological performance of the block-on-ring system. The maximum contact pressure is located at both edges of the scratch due to the formation of a water sac structure. The scratch has a great influence on the transition of the lubrication state of the block-on-ring system. The existence of scratches increases the critical speed at which the lubrication state transits from mixed-lubrication to elastohydrodynamic lubrication, and the critical speed is directly proportional to the scratch width. Full article

This study was designed to examine the effects of a trimethylolpropane trioleate (TMPTO)-based lubricant on thrust force and torque under the high-speed drilling of Al-6061 as an effective environmentally friendly cutting fluid. The tribological performance of three lubricant blends was evaluated based on ASTM standards. TMPTO base oil, notably enhances load-carrying capacity under extreme pressure conditions, with a seizer load of 7848 N. The best-performing oil was further optimized using a Taguchi-based design experiment to investigate the effect of different additive concentrations on thrust force and torque under actual contact conditions. Experiments were conducted using three critical machining parameters: additive concentration, spindle speed, and feed rate. The results of the ANOVA analysis reveal that spindle speed contributes most substantially (62.99%) to torque, with feed rate (23.72%) and additive concentration (7.74%) also showing significant impacts. On the other hand, thrust force is primarily influenced by feed rate (73.52%), followed by spindle speed (16.82%), and additive concentration (6.28%). Furthermore, a machine learning model was developed to predict and compare a few significant aspects of high-speed drilling machinability, including thrust force and torque. Three different error metrics were utilized in order to assess the performance of the predicted values, namely the coefficient of determination (R2), mean absolute percentage error (MAPE) and mean square error (MSE), which are all based on the coefficient of determination. Compared to other models, decision tree produces more accurate prediction values for cutting forces. The present study provides a novel approach for evaluating the most promising biodegradable lube oils and predicting cutting forces by formulating a perfect blend. Full article

A water hydraulic axial piston pump has become the preferred power component of environmentally friendly water hydraulic transmission systems, due to its advantages of a compact structure, high power density, and so on. The poor friction and wear performance in the water medium, especially under extreme conditions of high speed and high pressure, limit the engineering application of the water hydraulic axial piston pump. In this review, the research progress for key friction pair materials (such as special corrosion-resistant alloys, engineering plastics, and engineering ceramics) for water hydraulic axial piston pumps is, firstly, summarized. Secondly, inspired by nature, the processing methods, lubrication drag-reduction mechanism, and tribological properties of the biomimetic surface textures are discussed. The effects of the surface texture shape, equivalent diameter, depth, and arrangement on the pump’s tribological properties are reviewed in detail. Finally, the application status of, and problems with, surface texture technology in water hydraulic axial piston pumps are summarized. It is suggested that future studies should focus on the multi-field coupling lubrication anti-friction mechanism of the multi-type composite texture under extreme conditions and mixed lubrication; and the anti-wear performance of the texture coupled with a coating modification, to further promote the surface texture in the field of lubrication antifriction engineering applications. Full article

Water-based lubrication, due to the poor film-forming ability of water, faces challenges in achieving effective lubrication for titanium alloys. This study systematically investigates the frictional performance of phosphorus-based extreme pressure (EP) additives and self-emulsifying esters (SEE) on the surface of titanium alloy (TB6) under different pressures and temperatures. The core lubricant consists of SEE with nonylphenol polyoxyethylene ether phosphate ester (NPEP), polyoxyethylene oleyl ether phosphate ester (POEP), and alcohol ether phosphate ester (AEP). Results show that SEE significantly improves the film-forming ability of the aqueous solution, while phosphate ester forms a strong chemical adsorption film on the alloy surface via P-O-Ti covalent bonds, enhancing the strength of the lubricating film. The combination of SEE and phosphate esters in the water-based solution enables effective lubrication for titanium alloys. Particularly, the mixture of POEP and SEE demonstrates excellent synergistic effects, making it an ideal blend for water-based cutting fluids for titanium alloys. This study elucidates the lubrication mechanisms and action ranges between different additives, providing important guidance for the development and promotion of water-based cutting fluids. Full article

Vegetable oils have been used as metalworking fluids (MWFs) for many years, particularly in small-scale metalworking operations and in industries where environmental regulations are strict. Before the development of modern MWFs, vegetable oils were one of the most common lubricants used for metalworking tools. The use of vegetable oils can be traced back to ancient civilizations such as Egypt, Greece, and Rome, where olive oil was commonly used to lubricate metal tools and weapons. Today, vegetable oils are used as MWFs in a variety of applications. They are often combined with additives or nanoparticles to enhance their performance, such as improving the lubricity, cooling properties, and stability of the oil, as well as reducing friction and wear on the cutting tool. Additives, such as antioxidants, anti-wear agents, and extreme pressure (EP) additives, can be used to improve the performance of vegetable oils as cutting fluids. Compared to standard MWFs, vegetable oils are generally more biodegradable and environmentally friendly, and can be more cost-effective. However, MWFs may offer superior performance in certain areas, such as lubrication and cooling. Ultimately, the choice of MWFs will depend on the specific requirements of the metalworking operation and the balance between performance, cost, and environmental considerations. As the demand for sustainability and environmental responsibility continues, the use of vegetable oils as MWFs is likely to become even more popular in the future. Overall, vegetable oils offer a viable and potentially attractive alternative to standard MWFs in certain applications. This review highlights both conventional and most recent advances in vegetal oils frequently used as lubricant fluids in manufacturing processes. Full article

In order to increase the performance of tool or mold/die, there are a lot of micro features on the surface to provide special functions, such as anti-adhesion or lubrication. The MPB (Micro Particle Bombarding) process provides a powerful technology to enhance the surface quality without damaging the micro features. The effect of MPB parameters were investigated by bombarding the surface with extremely small particles (20~200 µm in diameter) at a high velocity and pressure to obtain a better surface integrity. -The MPB has two functions, one is micro blasting for cleaning purposes and the other is micro shot peening for surface strengthening. The regression relationship between particle bombarding time and micro hardness is established to predict the surface hardness after MPB process. The experimental results reveal that the surface hardness of cermet is increased 14~66% (HV2167~HV3163) by micro particle bombarding. The micro shot peening provides a good surface integrity due to thebetter surface roughness of 0.1 μmRa and higher compress residual stress of −1393.7 MPa, which is up to 26% enhancement compared with the base material cermet. After micro shot peening, the surface hardness of the SKD11 tool steel increased from HV 686 to HV 739~985. The surface roughness of SKD 11 after micro shot peening was 0.31–0.48 μmRa, while the surface roughness after micro blasting was 0.77–1.15 μmRa. It is useful to predict the residual stress for micro blasting by surface roughness, and to estimate the residual stress after micro shot peening by surface hardness by applying the MPB process in industry in the case of SKD 11 tool steel. Full article

The replacement of conventional lubricants with esters is an alternative to provide a low environmental impact and at the same time excellent lubricity features, the high solubility of additives, good viscosity index, low volatility, and high thermal stability. Friction modifiers and antiwear/extreme pressure additives are extensively used to save energy and increase operational life in machine components. In this study, the lubricity of a Group IV base oil containing ester and various benchmark friction modifiers and/or antiwear/extreme pressure additives is measured to evaluate the influence of the ester on the tribological performance of the mixture components. The tribological performance is discussed based on the tabulation of the traction coefficient using a Mini-Traction-Machine and on the measurement of the specific wear rate from the wear scar of the experimental studies using an optical profilometer. In general, results show synergies between the ester and the additive formulations, reducing the wear rate to 75% and decreasing the traction coefficient a 20 to 50%, depending on the evaluated additive. Full article

Hard and wear-resistant coatings created utilizing physical vapor deposition (PVD) techniques are extensively used in extreme tribological applications. The friction and wear behavior of coatings vary significantly with temperature, indicating that advanced coating concepts are essential for prolonged load-bearing applications. Many coating concepts have recently been explored in this area, including multicomponent, multilayer, gradient coatings; high entropy alloy (HEA) nitride; and functionally modified coatings. In this review, we highlighted the most significant findings from ongoing research to comprehend crucial coating properties and design aspects. To obtain enhanced tribological properties, the microstructure, composition, residual stress, hardness, and HT oxidation resistance are tuned through doping or addition of appropriate materials at an optimized level into the primary coatings. Such improvements are achieved by optimizing PVD process parameters such as input power, partial pressure, reactive gas flow rates, substrate bias, and temperature. The incorporation of ideal amounts of Si, Cr, Mo, W, Ag, and Cu into ternary and quaternary coatings, as well as unique multilayer designs, considerably increases the tribological performance of the coatings. Recent discoveries show that not only mechanical hardness and fracture toughness govern wear resistance, but also that oxidation at HT plays a significant role in the lubrication or wear failure of coatings. The tribo-induced metal oxides and/or Magnéli phases concentrated in the tribolayer are the key governing factors of friction and wear behavior at high temperatures. This review includes detailed insights into the advancements in wear resistance as well as various failure mechanisms associated with temperature changes. Full article