Automotive Lubricant Testing and Advanced Additive Development (ASTM special technical publication 1501)

143 Pages·2008·6.63 MB·English

by  Simon Tung

T
u
n
g
| K
in
k
e
r
| W Automotive
o
y
d
t
Lubricant Testing
and Additive Development
A
u
t
o
m
o
t
iv
e
L
u
b
r
ic
a
n
t
T
e
s
t
in
g
a
n
d
A
d
d
it
iv
e
D
e
v
e
lo
p
m
e
n
t
S
T
P
1
5
0
1
Simon Tung,
A Bernard Kinker,
S
T and Mathias Woydt
M
Int Editors
www.astm.org e
r
n
at STP 1501
ISBN: 978-0-8031-4505-4 io
n
STOCK #: STP1501 a
l
109343 ASTM OUTSIDE 1/4" HT-- PMS 7519 T
STP1501
Automotive Lubricant Testing
and Advanced Additive Development
Dr.SimonTung,Mr.BernardKinker,andDr.MathiasWoydt,editors
ASTM Stock Number: STP1501
ASTM
100 Barr Harbor Drive
PO Box C700
West Conshohocken, PA19428-2959
PrintedintheU.S.A.
Library of Congress Cataloging-in-Publication Data
Automotive lubricant testing and additive development / SimonTung, Bernard Kinker,
and Mathias Woydt, editors.
p. cm. — (cid:1)ASTM stock number: STP1501(cid:2)
ISBN: 978-0-8031-4505-4
1.Automobiles--Motors--Lubrication systems. 2.Automobiles--Lubrication. I.Tung,
Simon. II. Kinker, Bernard, 1945- III. Woydt, Mathias, 1963- IV.ASTM International.
TL214.O5A98 2008
629.25’5--dc22
2007051559
Copyright © 2008 AMERICAN SOCIETY FOR TESTING AND MATERIALS
INTERNATIONAL, West Conshohocken, PA.All rights reserved.This material may not
be reproduced or copied, in whole or in part, in any printed, mechanical, electronic,
film,orotherdistributionandstoragemedia,withoutthewrittenconsentofthepublisher.
Photocopy Rights
Authorization to photocopy items for internal, personal, or educational
classroom use, or the internal, personal, or educational classroom use of
specific clients, is granted by theAmerican Society for Testing and Materials
International „ASTM… provided that the appropriate fee is paid to the Copyright
Clearance Center, 222 Rosewood Drive, Danvers, MA 01923; Tel: [phone];
online: http://www.copyright.com/.
Peer Review Policy
Each paper published in this volume was evaluated by two peer reviewers and at
leastoneeditor.Theauthorsaddressedallofthereviewers’commentstothesatisfaction
ofboththetechnicaleditor(cid:1)s(cid:2)andtheASTMInternationalCommitteeonPublications.
The quality of the papers in this publication reflects not only the obvious efforts of
the authors and the technical editor(cid:1)s(cid:2), but also the work of the peer reviewers. In
keeping with long-standing publication practices,ASTM International maintains
theanonymityofthepeerreviewers.TheASTMInternationalCommitteeonPublications
acknowledges with appreciation their dedication and contribution of time and effort
on behalf ofASTM International.
Printed in Mayfield, PA
April, 2008
Foreword
This publication, Automotive Lubricant Testing and Advanced Additive Development,
contains peer reviewed papers from the above symposium, organized by committee
D02,inDecember,2006atLakeBuenaVista,Florida.Thissymposiumwasinconjunc-
tion with the D02 sub-committee “Fuels and Lubricants”. The symposium Co-Chairs
were Dr. SimonTung, General Motors, Warren, MI, Mr. Bernard Kinker, Rhomax, USA,
Horsham,PA,andDr.MathiasWoydt,BAM,FederalInstituteforMaterialsResearchand
Testing, Berlin, Germany.

Contents
Overview vii
AReviewofEngineOilOxidationBenchTestsandTheirApplicationintheScreening
ofNewAntioxidantSystemsforLowPhosphorusEngineOils—V.GATTO,
W.MOEHLE,ESCHNELLER,T.BURRIS,T.COBB,ANDM.FEATHERSTONE 1
ViscometricTemperatureSensitivityofEngineLubricantsatLowTemperature
andModeratelyHighShearConditions—K.O.HENDERSONANDC.P.MAGGI 14
No/LowSAPandAlternativeEngineOilDevelopmentandTesting—M.WOYDT 35
SynergisticTribologicalPerformancesofBorateAdditiveinLubricants—J.-Q.HU,
Y.-Q.HU,G.-L.LIU,ANDY.-H.MA 48
The‘‘PracticeRelevantPittingTest’’—ANewImprovedTestMethodtoEvaluate
the Influence of Lubricants on the Pitting Load Capacity of Case
CarburizedGears—B.-R.HOHN,P.OSTER,T.RADEV,ANDT.TOBIE 57
ROBO—ABenchProceduretoReplaceSequenceIIIGAEngineTest—B.G.KINKER,
R.ROMASZEWSKI,ANDP.A.PALMER 66
MechanochemicalAdditive-AssistedReconditioningEffectsandMechanismonWorn
FerrousSurfaces
—J.YUANSHENG,Y.HE,ANDL.SHENGHUA 79
StudyoftheZDDPAntiwearTribofilmFormedontheDLCCoatingUsingAFM
andXPSTechniques—T.HAQUE,A.MORINA,A.NEVILLE,R.KAPADIA,
ANDS.ARROWSMITH 92
ValidationofOxidativeStabilityofFactoryFillandAlternativeEngineOilsUsing
theIronCatalyzedOxidationTest
—E.FITAMEN,L.TIQUET,ANDM.WOYDT 103
AdditiveandBaseOilEffectsinAutomaticParticleCounters—P.W.MICHAEL,
T.S.WANKE,ANDM.A.MCCAMBRIDGE 109
DesignofFunctionalizedPAMAViscosityModifierstoReduceFrictionandWear
inLubricatingOils—M.MÜLLER,J.FAN,ANDH.SPIKES 116
SurfaceCharacterizationTechniquesinWearofMaterials—K.MIYOSHI,K.ISHIBASHI,
ANDM.SUZUKI 126
v

Overview
Thisbookrepresentstheworkofseveralauthorsatthe1stSymposiumorganizedbyD02tofocus
onautomotivelubricanttestingandadvancedadditivedevelopment.Thissymposiumwasheldat
LakeBuenaVista,Florida,inconjunctionwiththemeetinginDecember2006oftheASTMD02
sub-committee “Fuels & Lubricants”.
Inordertohelpautomotiveindustrymeetloweremissionstandards,higherfueleconomygoals,
and loger drain intervals associated with a minimization of any adverse effects of lubricants to
the environment, the petroleum industries and the additive suppliers are developing low SAPS
(cid:1)sulfatedash,phosphorusandsulfur(cid:2)andhightribologicalperformancelubricantstomeetthese
challenges. New developments in powertrain system design and advanced additive formulation
areessentialinaddressingtheseproblems.ThisASTMsymposiumhasprovidedanoutstanding
forum to discuss how OEMs and lubricant companies are solving real engineering problems to
increase fuel economy and meet emissions legislation together. This symposium publication is
focusedonboththechemicalandtribologicalaspectsofthefunctionalperformanceofautomo-
tivelubricantandtesting.Inthissymposium,recentadvancesinadditiveandbaseoilchemistry
and function have been covered in details; product formulation for engine performance and the
link between additive chemistry and emissions have been discussed. Tribological performance
issues such as fuel economy retention, wear protection and friction reduction as well as their
retention over drain, engine durability, and future challenges, including advanced powertrain
developments,newlubricanttestmethodsoutsideoftheapplication,lubricantformulations,and
correlation between lubricant formulation and engine performance are the key subjects.
Papersandpresentationsaretargetedtoprovideacomprehensiveoverviewofvariouslubrication
testmethodsforatypicalenginesystemincludingtheoxidationtestsforscreeningantioxidants
andbaseoils,benchweartests,enginesequencetestdevelopment,andoilconditionmonitoring
techniques,aswellasthemajortechnicalissuesonlubricantdegradationandthesurfacemecha-
nisms of ZDDPtribofilms interacted with advanced DLC coatings.
SeveralpapersdescribesthelowSAPlubricantdevelopmentandtesting,theimpactofadditive
and base oil on engine oil characteristics, the current industrial standard tests methods for
lubricantoxidationstability,surfacepitting,andalternativeengineoildevelopment.Someofthe
papersdiscussthesynergisticeffectsoflubricantadditiveformulationandsurfacecoatingswhile
others concentrated on the coverage of various surface engineering applicators in practice.
This particular surface engineering area continues to be the major activity of many industrial
researchers.
As in the past ASTM lubricant symposium lubricant formulation technology was always a
critical focus theme. ThisASTM symposium was no exception. The diversity demonstrated in
this symposium exemplified the critical role of the lubricant formulation issues which was
influencedbyrecentautomotivehardwarechanges.PapersrangedfromadiscussionoflowSAP
lubricantsandvalidationofoxidationstabilityforfactoryfillandalternativeengineoilsusedin
new automotive emission system. Impact of emission regulations and hardware changes on
lubricantformulationsalsowasdiscussedthissymposium.Inaddition,theadditivedevelopment
addressing surface interaction studies between advanced materials and lubricants plays an im-
portant role for automotive hardware changes.
vii
Onthebehalfofalleditorsandchairs,wewouldliketothanktheoutstandingcontributionsfrom
all authors and speakers in this symposium for making our 1st automotive lubricant testing and
additivedevelopmentsymposiumverysuccessful.Thankyouforyourparticipation.Wehopewe
will organize another symposium in the near future.
Dr. Simon Tung
General Motors
Warren, MI
Mr. Bernard Kinker
Rhomax, USA
Horsham, PA
Dr. Mathias Woydt
BAM, Federal Institute for Materials Research andTesting
Berlin, Germany
viii
JournalofASTMInternational,Vol.4,No.7
PaperIDJAI100849
Availableonlineatwww.astm.org
Vincent Gatto,1 William Moehle,1 Emily Schneller,1 Thalan Burris,1
Tyler Cobb,1 and Mark Featherstone1
A Review of Engine Oil Oxidation Bench Tests and Their
Application in the Screening of New Antioxidant Systems for
Low Phosphorus Engine Oils
ABSTRACT:Areviewofcurrentoxidationanddepositbenchtestsusedfortheevaluationofengineoil
performancewillbepresented.Someofthemoremeaningfultestswillbeutilizedtoevaluateanumberof
antioxidantsystemsforoxidationanddepositcontrolcapabilitiesinengineoilsformulatedwith470ppmof
ZDDP-derivedphosphorus.Theantioxidantcomponentsareselectedfromaseriesofcommonlyusedand
commerciallyavailablematerialsplusonenewdevelopmentalcomponent.Thesecomponentsincludean
organo-molybdenumcompound(cid:1)MoDTC(cid:2),analkylateddiphenylamine(cid:1)NDPA(cid:2),aconventionalhindered
phenolic(cid:1)HPE(cid:2),ahighperformancehinderedphenolic(cid:1)MBDTBP(cid:2),andanewmulti-functionalboronated
MBDTBP.Theperformanceofthesefullyformulatedengineoilswillberankedintheselectedbenchtests
inordertohighlightthebenefitsofeachantioxidantsystemunderevaluation.Theresultspointtosignificant
benefits with the molybdenum- and boronated-systems, or mixed molybdenum-/boronated-systems, for
oxidation control, while systems containing NDPAand MBDTBP are favored more for deposit control.
Uniqueandsuperiorperformingantioxidantsystemswillberecommendedforscreeninginfiredengineand
benchweartests.
KEYWORDS: oxidation, viscosity increase, stabilization, deposits, antioxidants, engine oil, bench
tests
Introduction
Inrecentyearsgreaterperformancedemandshavebeenplacedonengineoilstodeliversuperioroxidation
anddepositcontrolprotection.Thishasoccurredconcurrentlywiththemandatedreductionsofphosphorus
driven by concerns to protect engine catalyst systems. This has forced the use of lower levels of zinc
dalkyldithiophosphate (cid:1)ZDDP(cid:2) in modern engine oils. Such formulation changes have had a number of
negativeimpactsonengineoilperformance.ZDDPisknowntobeoneofthemostcosteffectiveantioxi-
dantsandantiwearadditivesavailable.Reductionsinitsusemustbecompensatedforbytheuseofother
phosphorus-free components.Achallenge exists for the engine oil formulator to identify the most cost
effectivealternativestoZDDPusinginexpensiveyetmeaningfulbenchtesttechniques.
Figure1illustratesoneexampleofthetechnicalchallengelubricantformulatorsmustaddresswhen
movingtolowerphosphorusengineoils.ThechartshowsTEOSTMHT® resultsfortwo5W-30engine
oils containing varying amounts of phosphorus from ZDDP. The chart also highlights the GF-3 and
proposed GF-5 passing limits for maximum deposits in the TEOST®. Note that the passing limits have
droppedfrom45to25mgwiththeadvanceofthecategory,whilethedepositformingtendencyofthetest
oil has increased from 30 to 64mg.This observed change is due exclusively to the reduction in ZDDP
level.
Depositformationisjustoneaspectassociatedwithlubricantoxidation.Parameterssuchasviscosity
increase and varnish formation are critical performance measures in a variety of fired sequence engine
tests.WhileitisconceivabletodevelopengineoilsaroundTEOST®performance,itbecomesimpractical
fromacostandtimestandpointtousesequenceengineteststooptimizeforalloxidationparameters.This
has recently led to increased interest in oxidation bench tests to optimize engine oil formulations for
ManuscriptreceivedOctober16,2006;acceptedforpublicationJuly9,2007;publishedonlineAugust2007.PresentedatASTM
Symposium on Automotive LubricantTesting andAdditive Development on 3–5 December 2006 in Lake BuenaVista, FL;
SimonTung,BernardKinker,andMathiasWoydt,GuestEditors.
1AlbemarleCorporation,P.O.Box341,BatonRouge,LA70821.
Copyright©2007byASTMInternational,100BarrHarborDrive,POBoxC700,WestConshohocken,PA19428-2959.
1