Lubricants and Lubrication, Second Edition

893 Pages·2007·8.129 MB·English

LubricantsandLubrication
EditedbyTheoMangandWilfriedDresel
LubricantsandLubrication.2ndEd.EditedbyTh.MangandW.Dresel
Copyright(cid:1)2007WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:978-3-527-31497-3
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Lubricants and Lubrication
Edited by
Theo Mang and Wilfried Dresel
Second, Completely Revised and Extended Edition
Editors & AllbookspublishedbyWiley-VCHare
carefullyproduced.Nevertheless,authors,
Prof.Dr.TheoMang editors,andpublisherdonotwarrantthe
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(cid:1)2007WILEY-VCHGmbH,Weinheim
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ISBN 978-3-527-31497-3
V
Listof Contributors
ThorstenBartels DietrichH(cid:2)rner
Dr.-Ing.,WeisenheimamSand,Germany Dr.rer.nat.,Hassloch,Germany
TechnicalServiceManagementandTestLab InternationalProductManagementfor
Management MetalworkingFluidsandQuenchingOils
WolfgangBock FranzKubicki
Dipl.-Ing.,Weinheim,Germany Dipl.-Ing.,Hockenheim,Germany
InternationalProductManagementIndustrialOils InternationalProductManagementforCorrosion
PreventivesandSheetMetalforming
J(cid:1)rgenBraun
Dr.rer.nat.,Speyer,Germany GeorgLingg
R&DforIndustrialOils Dr.-Ing.,Mannheim,Germany
MemberoftheExecutiveBoard,Technologyand
ChristianBusch SupplyChain
Dr.-Ing.,Kaiserslautern,Germany
ManagingDirector AchimLosch
Dr.rer.nat.,Westhofen,Germany
WolfgangBuss R&DforCorrosionPreventives,Metalformingand
Dr.rer.nat.,Freinsheim,Germany Cleaners
R&DandProductManagementforForming
Lubricants RolfLuther
Dipl.-Phys.,Speyer,Germany
WilfriedDresel HeadofTestFieldsandAdvancedDevelopment
Dr.rer.nat.,Ludwigshafen,Germany
R&DforLubricatingGreases(International) TheoMang
Prof.Dr.-Ing.,Weinheim,Germany
CarmenFreiler Group’sExecutiveBoard,Technology,Group
Dipl.-Ing.,H(cid:2)ttenfeld,Germany Purchasing,HumanResources(until2001)
R&DandProductManagementforMetalCutting
Fluids RomanM(cid:1)ller
Mannheim,Germany
ManfredHarperscheid InternationalKnow-HowTransfer
Dr.rer.nat.,R(cid:3)merberg,Germany
R&DforEngineOils SiegfriedNoll
Chemist,Mannheim,Germany
Rolf-PeterHeckler RawMaterialSpecifications,CentralPurchasing
Dipl.-Ing.,Neu-Isenburg,Germany andGeneralManagement(†2003)
InternationalProductManagementfor
LubricatingGreases J(cid:1)rgenOmeis
Dr.rer.nat.,Zwingenberg,Germany
R&DforEngineOils(until2004)
LubricantsandLubrication.2ndEd.EditedbyTh.MangandW.Dresel
Copyright(cid:1)2007WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:978-3-527-31497-3

VII
Contents
ListofContributors V
Preface,Foreword2ndedition XXXIII
AWordofThanks XXXV
ListofAbbreviations XXXVII
1 LubricantsandtheirMarket 1
TheoMang
1.1 Preface 1
1.2 LubricantSales 2
1.3 TheLubricantsIndustry 3
1.4 LubricantSystems 5
2 LubricantsintheTribologicalSystem 7
TheoMang
2.1 LubricantsasPartofTribologicalResearch 7
2.2 TheTribologicalSystem 8
2.3 Friction 8
2.3.1 TypesofFriction 9
2.3.1.1 SlidingFriction 9
2.3.1.2 RollingFriction 10
2.3.1.3 StaticFriction 10
2.3.1.4 KineticFriction 10
2.3.1.5 Stick–Slip 10
2.3.2 FrictionandLubricationConditions 12
2.3.2.1 SolidFriction(DryFriction) 12
2.3.2.2 BoundaryFriction 12
2.3.2.3 FluidFriction 13
2.3.2.4 MixedFriction 13
2.3.2.5 SolidLubricantFriction 13
LubricantsandLubrication.2ndEd.EditedbyTh.MangandW.Dresel
Copyright(cid:1)2007WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:978-3-527-31497-3
VIII Contents
2.3.2.6 StribeckDiagram 14
2.3.2.7 HydrodynamicLubrication 14
2.3.2.8 Elasto–HydrodynamicLubrication(EHDRegime) 15
2.3.2.9 Thermo-elasto-hydrodynamicLubrication(TEHD) 15
2.4 Wear 17
2.4.1 WearMechanisms 17
2.4.1.1 Abrasion 17
2.4.1.2 Adhesion 17
2.4.1.3 TribochemicalReactions 17
2.4.1.4 SurfaceFatigue 17
2.4.1.5 Erosion 18
2.4.1.6 Fretting 18
2.4.1.7 Cavitation 18
2.4.2 TypesofWear 18
2.4.3 TheWearProcess 18
2.4.4 Tribomutation 19
2.4.5 Nanotribology 20
2.4.6 TribosystemsofTomorrow 22
3 RheologyofLubricants 23
TheoMang
3.1 Viscosity 23
3.2 InfluenceofTemperatureonViscosity(V–TBehavior) 25
3.2.1 ViscosityIndex 26
3.3 Viscosity–PressureDependency 27
3.4 TheEffectofShearRateonViscosity 28
3.5 SpecialRheologicalEffects 30
3.5.1 Greases 31
3.6 ViscosityGrades 31
3.6.1 ISOViscosityGrades 32
3.6.2 OtherViscosityGrades 32
3.6.2.1 EngineOils 32
3.6.2.2 AutomotiveGearOils 32
3.6.2.3 IndustrialGearOils 32
3.6.2.4 ViscosityGradesforBaseOils 33
3.6.2.5 ComparisonofViscosityGrades 33
4 BaseOils 34
TheoMangandGeorgLingg
4.1 BaseOils–AHistoricalReviewandOutlook 34
4.2 ChemicalCharacterizationofMineralBaseOils 35
4.2.1 RoughChemicalCharacterization 35
4.2.1.1 Viscosity–GravityConstant(VGC) 35
4.2.1.2 AnilinePoint 35
Contents IX
4.2.2 CarbonDistribution 36
4.2.3 HydrocarbonComposition 36
4.2.4 PolycyclicAromaticsinBaseOils 36
4.2.4.1 AromaticsinWhiteMineralOils 37
4.3 Refining 38
4.3.1 Distillation 39
4.3.2 De-asphalting 39
4.3.3 TraditionalRefiningProcesses 40
4.3.3.1 AcidRefining 41
4.3.3.2 SolventExtraction 41
4.3.4 SolventDewaxing 43
4.3.5 Finishing 44
4.3.5.1 LubeCrudes 44
4.4 BaseOilManufacturingbyHydrogenationandHydrocracking 45
4.4.1 ManufacturingNaphthenicBaseOilsbyHydrogenation 46
4.4.2 ProductionofWhiteOils 48
4.4.3 LubeHydrocracking 49
4.4.4 CatalyticDewaxing 50
4.4.5 WaxIsomerization 52
4.4.6 HybridLubeOilProcessing 52
4.4.7 All-HydrogenRoute 53
4.4.8 Gas-to-LiquidsConversionTechnology 55
4.5 BoilingandEvaporationBehaviorofBaseOils 55
4.6 BaseOilCategoriesandEvaluationofVariousPetroleumBaseOils 59
5 SyntheticBaseOils 63
WilfriedDresel
5.1 SyntheticHydrocarbons 64
5.1.1 Polyalphaolefins 65
5.1.2 Polyinternalolefins 67
5.1.3 Polybutenes 68
5.1.4 AlkylatedAromatics 69
5.1.5 OtherHydrocarbons 70
5.2 HalogenatedHydrocarbons 71
5.3 SyntheticEsters 71
5.3.1 Estersofcarboxylicacids 71
5.3.1.1 DicarboxylicAcidEsters 72
5.3.1.2 PolyolEsters 73
5.3.1.3 OtherCarboxylicEsters 74
5.3.1.4 ComplexEsters 75
5.3.1.5 FluorinatedCarboxylicAcidEsters 76
5.3.2 PhosphateEsters 76
5.4 PolyalkyleneGlycols 77
5.5 OtherPolyethers 79
X Contents
5.5.1 PerfluorinatedPolyethers 79
5.5.2 PolyphenylEthers 80
5.5.3 Polysiloxanes(SiliconeOils) 81
5.6 OtherSyntheticBaseOils 83
5.7 ComparisonofSyntheticBaseOils 87
5.8 MixturesofSyntheticLubricants 87
6 Additives 88
J(cid:1)rgenBraun
6.1 Antioxidants 89
6.1.1 MechanismofOxidationandAntioxidants 89
6.1.2 Compounds 91
6.1.2.1 PhenolicAntioxidants 91
6.1.2.2 AromaticAmines 91
6.1.2.3 CompoundsContainingSulfurandPhosphorus 92
6.1.2.4 OrganosulfurCompounds 92
6.1.2.5 OrganophosphorusCompounds 93
6.1.2.6 OtherCompounds 93
6.1.2.7 SynergisticMixtures 93
6.1.3 TestingoftheOxidationStability 93
6.2 ViscosityModifiers 94
6.2.1 PhysicalDescriptionofViscosityIndex 94
6.2.2 VIImprovementMechanisms 94
6.2.3 StructureandChemistryofViscosityModifiers 96
6.3 PourpointDepressants(PPD) 97
6.4 DetergentsandDispersants 99
6.4.1 MechanismofDDAdditives 100
6.4.2 Metal-containingCompounds(Detergents) 100
6.4.2.1 Phenates 100
6.4.2.2 Salicylates 100
6.4.2.3 Thiophosphonates 101
6.4.2.4 Sulfonates 102
6.4.3 AshlessDispersants(AD) 103
6.5 AntifoamAgents 105
6.5.1 SiliconDefoamers 105
6.5.2 Silicone-freeDefoamers 106
6.6 DemulsifiersandEmulsifiers 106
6.6.1 Demulsifiers 106
6.6.2 Emulsifiers 106
6.7 Dyes 107
6.8 Antiwear(AW)andExtremePressure(EP)Additives 107
6.8.1 FunctionofAW/EPAdditives 107
6.8.2 Compounds 108
6.8.2.1 PhosphorusCompounds 108