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LUBRICANTSTopics
Definition Classification Mechanism of lubrication Properties Solid lubricantsOn viewing under an electron microscope, the surface of even a mirror polished metallic surface exhibits
irregularity. The peaks are called asperities and the valleys are called pits
Scanning Electron Microscopic Picture of Mirror Polished Platinum Surface
Asperities and Valleys on two sliding surfaces
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Types of Friction: There are two types of friction (Static and Dynamic)
Sliding Friction: Two flat Surfaces in motion Rolling Friction: At least one moving surface is spherical
Frictional Heat and Welded Joints
Ar= Real area of contact, junction, high stress, plastic deformation, adhesive bonding
B = Area filled with oxides, lubricant or air
Micro weld is the area where invisible welded joints are formed
N = Normal force
F = Frictional force
Definition
Substances introduced between moving surfaces in order to reduce friction and thusprevent welded joints and seizure, are called Lubricants
The process of prevention of metal to metal contact by means of an intervening layer offluid or fluid like material is termed as Lubrication
Functions of Lubricants
It acts as a thermal barrier and reduces friction and wear and prevents welded joints Avoids seizure of moving surfaces Acts as coolant Acts as a seal and prevents entry of dust, moisture, & dirt between moving parts
Ar B
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Some lubricants acts as corrosion inhibitors thus reduce operational costClassification: Three Different types of classifications are done
Based on occurrence / Source Based on lubricant Physical State
Based on Lubrication process
Liquid lubricant examples: 1. Animal oils - Lard oil, Tallow oil, Whale oil 2. Vegetable oil - Castor oil, Palm oil, Coconut oil 3. Mineral based - Petroleum fractions 4. Emulsions
O/ W Cutting liquids
W / O Cooling liquids
5. Synthetic oils blended mineral oils
Source
NaturalRubber, graphite
SyntheticSilicones, greases
Physical
SolidMoS2 ,Talc , Mica Silicone, Graphite and
Semisolid
Greases VaselineLiquid (oil)
1. 432
O/W W/O
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Thick Film / Fluid film / Hydrodynamic Lubrication
In this type a continuous fluid film exists between the sliding surfaces
Employed when the sliding velocity is moderate and load is low Used for machineries operated continuously In fluid film lubrication, the fluid immediately adjacent to each surface travels at the
same speed and direction of each surface.
Film thickness is 1000 A Factors which affect the thickness of hydrodynamic fluid film include lubricantviscosity, rotation speed or RPM, oil supply pressure, and component loading.
An increase in speed or viscosity increases oil film thickness. An increase in load decreases oil film thickness. Coefficient of friction is 0.001 to 0.03 cm/sec Blended Mineral oils are used to introduce a thick film between sliding surfaces Finds application in watches, clocks and scientific instrument (stop watches) Hydrodynamic lubrication often occurs in components such as cylinders, gears, and plain
bearings
Mechanism
Thick film
Greases, Vaseline
Thin film
Blended mineral oils
Extreme Pressure
Oil with chlorinated ester
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Boundary Lubrication / Thin film
Boundary lubrication often occurs during the startup and shutdown of equipment, or when
loading becomes excessive.
Low speed , high load & non continuous operation Thickness is 20 30 A
Coefficient of friction is 0.05 0.15 cm /sec Film formation by either Physisorption or chemisorption Oiliness should be high Fatty acids and their soaps are used as additives Used in automobiles and heavy machinery Certain types of gear sets that need to withstand sliding pressures and shock loading,
such as hypoid gears use boundary lubricants
a and b Thick film lubrication
c and d - Thin film lubrication
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Extreme Pressure Lubricants
Extreme pressure lubricants interact with metal surfaces in a chemical process, at molecular
level, to create a protective compound which increases the thermal stability of metal surfaces.
This is not a film or coating over the metal. It is a permanent modification of the metalsurface
Molecules in the extreme pressure lubricants are polarized and actually bond with the metal
surface
It is applicable in High load and high speed condition
Metal surface should be active (Fe, Cu etc.,) Lubricants containing Chlorinated ester/ Sulphurised oils / Tricresyl phosphate are used Surface compounds is formed due to chemisorption (ex.sulphurised oil containing
lubricants reacts with Iron and forms Iron sulphide whose thermal stability is better thanmere iron)
The thickness of the surface compound is a few molecule layer Co. efficient of friction 0.1 0.4 cm /sec It finds application in Air crafts and space crafts Unique character of this type of lubricants is its replenish ability / easy of
replacement
Extreme pressure
lubricant
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Important Properties
1. Viscosity and Viscosity Index
Viscosity is defined as Resistance to flow Viscosity Index is the measure of resistance to change in viscosity Viscosity Index (V.I) is value representing the degree for which the oil viscosity changes
with temperature.
If change in viscosity ( ie decrease in viscosity with increase in temperature) is small , theoil is said to have a high viscosity index.
Low viscosity does not mean Low VI (Ex. Viscosity of water is less but VI of water ishigh)
Viscosity Index is measured using Red wood (Common Wealth Countries) Viscosity Index is measured using Say bolt viscometer (USA) Viscosity Index is measured using Engler viscometer (European countries) Naphthalenic base Gulf oils have Low viscosity index (VI =0 , L series oils) Paraffinic base Pennsylvanian oils have high viscosity index (VI =100, H series oils)
The viscosity of test oil is measured at 100
o
F and 210
o
F
An oil possessing the same viscosity as that of test oil at 210 oFis chosen from both L and H series
Their corresponding viscosities at 100oF is noted from the series ( L and H) If the viscosity of the test oil at 100oF is considered as U then its VI can be
calculated using the formula
V.I. = (L U / L H) x 100
Polymers and copolymers of olefins, methacrylates, dienes or alkylated styrenes areused as viscosity index improvers
When the oil gets heated up due to frictional heat, the viscosity of the oil decreases . The solubility of a polymeric molecule increases with increase in temperature which
results in the increase in viscosity
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Hence at elevated temperatures, the decrease in the viscosity of the oil will be balancedby the solubility of the polymer in oil. Thus polymers act as good VI improvers
Good motor oil has a high V.I.(For diagram, description and working of Red wood viscometer refer Text book - 190OR class notes)
2. Tackiness / oiliness / lubricity
Oiliness is defined as the ability of the oil to stick firmly to a solid surface Oiliness should be high for a good lubricant Can be improved using additives long chain fatty acids and soaps are generally used as
tackiness improvers
Very essential in Boundary lubrication as tackiness improves replenish ability of thesurface film
3. Cloud and Pour Points
Cloud point is defined as the minimum temperature at which oil becomes hazy Pour point is defined as the minimum temperature at which oil stops pouring( or ceases
to flow)
When oil is cooled , wax starts crystallizing , and the oil becomes hazy Tiny wax crystals agglomerate and form bigger crystal lattice, at this stage the oil
solidifies completely and does not pour out on tilting.
Both cloud and Pour points should be very less than the operating temperature Cloud and pour points can be reduced by adding depressants Polymeric additives such as poly amino alcohols are added to decrease cloud and pour
points
Other pour point depressants include alkylated naphthalenes and phoenolic polymers,poly methacrylates, maleata/fumarate and copolymer esters
The additives lower the pour point either by forming a thin coating over wax and preventit from agglomerisation or co precipitate along with wax , thus reducing the freezingpoint
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(For diagram, description and working of cloud and pour point apparatus refer Text
book - 194 OR class notes)
4.Flash and fire Points
Flash point is defined as the lowest temperature at which the oil gives off just enoughvapours which gives out a flash when an open (tiny ) flame is brought near the vapours
Fire point is the lowest temperature at which the oil gives off enough vapours whichburns continuously at least for 5 seconds
Flash and Fire points should be high for a good lubricant Flash and fire point additives are used to increase the performance of a lubricant
CTFE is added to increase flash and fire points as it increases the vaporization point oflubricants
Usually there is a difference of 5 40o C between both for a good lubricant
(For diagram, description and working of Pensky Marten apparatus refer Text book -
192 OR class notes)
Blended oils
Practically no single lubricant will be able to satisfy all the properties of a good lubricant.
Hence it is essential to add various additives to achieve the required performance.
The process of adding different substances to impart a special character to the base oil is called
blending and the resulting oil is called blended oil.
The following table gives the various additives and their function in synthetic oils / blended oils
Name of the additive Substance added to
lubricating oils
Function
Oiliness
Fatty acids like stearic acid,
palmitic acid, oleic acidVegetable oils
Increases lubricity
Prevent rupture of film
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Extreme Pressure
additives
Organic chlorine
compounds / organicsulphur compounds /
phosphorous compounds
Form surface compounds
which has better thermalstability & wear resistance
Viscosity Index improvers n-hexanol, polyalkylbenzene, polyisobutylene
Reduce the rate of changeof viscosity with
Temperature
Pour point depressants Phenols, chlorinated
hydrocarbons
Prevent the agglomerisation
of wax which separates outfrom the lubricating oils
Thickeners Polystyrene, polyesters Increase the viscosity oflubricating oils
Antioxidants Phenolic compds, aromatic
amines
Prevent oxidation of oil.
Prevent gum formation
Deposit inhibitors /
detergents/ deflocculents
Salts of carboxylic acid /salts of phenols/
sulphonates
Reduce deposits in engineswhich block the passage of
oil
Corrosion inhibitors Organic compounds ofPhosphorous / antimony
Get adsorbed on metalsurface and protect the
surface from attack by
moisture
Solid lubricants
Solid lubricants are deposited in the valleys to create a smoother surface.
They are designed to protect against metal contact by coming between two peaks at
the moment of contact.
This results in the deformation of the peak, rather than formation of welded joints.
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Even between highly loaded stationary surfaces the lamellar structure is able to
prevent contact.
Large lubricant particles perform better on relative rough surfaces and at low speed,while finer particle perform better on smooth surface and higher speeds
(1stand 2ndare sliding surfaces and 3rdis solid lubricant filling the valley)
Layered Compounds like graphite , boron nitride ,molybdenum di sulphide , talc ,teflon, mica, calcium fluoride , cerium fluoride, tungsten disulfide etc are as
solid lubricants used
Graphite (organic substance) and molybdenum disulfide (MoS2 is inorganicsubstance) are the predominant materials used as solid lubricant due to their
lamellar structure
The lamellas orient parallel to the surface in the direction of motion and shearsover each other easily, resulting in a low friction.
Graphite
Graphite is a form of carbon which exists as a stack of 'sheets' of carbonatoms, each sheet having a hexagonal arrangement of atoms
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Three valencies are satisfied by covalent bonds and the fourth is weak VanderWaals Force
Both crystalline and amorphous form of graphite find application as lubricant,however amorphous graphite does not possess high shear strength hence usedonly when load is low.
Both natural and synthetic graphite can be used as lubricants Graphite is soapy to touch and non inflammable The C-C bond length is 1.42A and the distance between two hexagonal planes is
3.4A
It is stable up to 375oC (in presence of air) Water vapor is a necessary component for graphite lubrication. The adsorption of water reduces the bonding energy between the hexagonal
planes of the graphite Because water vapor is a requirement for lubrication, graphite is not effective
in vacuum Graphite is usually mixed with oil / water/ greases Graphite mixed with oil is called oil dag and graphite mixed with water is called
aqua dag
It is used to lubricate air compressors , railway track joints , food stuffindustries , IC engines etc.,
Molybdenum di Sulphide
Just like graphite, MoS2 also has a hexagonal crystal structure with theintrinsic property of easy shear
MoS2lubrication performance often exceeds that of graphite and is effectivein vacuum also
Mo layer is sandwiched between two sulphur layers Like graphite it has weak van der Waals forces between the basal planes.
The bonds between the sulfur layers are weaker than the bonds between themolybdenum layers.
The Metallic bond length , Mo-Mo is 3.08A , the covalent bond length S-S is3.15 A and the distance between two lamellas is 3.13A
It is stable up to 425oC in presence of air and up to 800oC in absence of air
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It is chemically inert It may be used in the form of powder/ mixed with oil or greases Water is not essential for its lubricity hence can be used in vacuum too in fact
its lubricity decreases in presence of water
It is used in IC engines