MultiMulti--componentcomponent NanoparticleNanoparticle BasedBased LubricantLubricant AdditiveAdditive toto ImproveImprove EfficiencyEfficiency AndAnd DurabilityDurability inin EnginesEngines
Dr. Atanu Adhvaryu (PI) Caterpillar Inc.
“This presentation does not contain any proprietary or confidential information”
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. DOE Contract: DE-FC26-07NT43277 ©2008 Caterpillar All Rights Reserved Aug 7, 2008
Caterpillar Confidential Yellow Outline
9 Objectives 9 Technical Challenges 9 Approach 9 Nano-lubrication mechanism 9 Performance measures and key results 9 Concluding remarks
Caterpillar Confidential Yellow Project Objectives (P1)
Design and optimize process for nanoparticle synthesis
Analyze shape, size, and surface properties
Understand agglomeration and improve suspension of hybrid nanoparticles
Lubrication mechanism and tribological behavior
Caterpillar Confidential Yellow Technical Challenges
¾ Prevent progressive wear, lower friction and improve efficiency and durability in engine components
Caterpillar Confidential Yellow Technical Challenges
¾ Prevent progressive wear, lower friction and improve efficiency and durability in engine components
¾ Additive system for lubricants that will minimize sulfur and phosphorus content and lower ash forming elements (Low SAPS)
Caterpillar Confidential Yellow Technical Challenges
¾ Prevent progressive wear, lower friction and improve efficiency and durability in engine components
¾ Additive system for lubricants that will minimize sulfur and phosphorus content and lower ash forming elements (Low SAPS)
¾ Advanced lubrication technology for cleaner emission
Caterpillar Confidential Yellow Technical landscape for SAPS SAPS – Sulphated Ash, Phosphorus and Sulfur
For HDEO (heavy duty diesel engine oil) SAPS are extremely effective for controlling wear, oxidation and limiting deposit formation. SAPS contribute to poisoning aftertreatment devices.
Caterpillar Confidential Yellow Technical landscape for SAPS SAPS – Sulphated Ash, Phosphorus and Sulfur
For HDEO (heavy duty diesel engine oil) SAPS are extremely effective for controlling wear, oxidation and limiting deposit formation. SAPS contribute to poisoning aftertreatment devices.
SAPS will not go away soon. They will reduce over time. Industry sees great potential for Mo based technologies to control oxidation, wear and deposit control
Caterpillar Confidential Yellow Technical landscape for SAPS SAPS – Sulphated Ash, Phosphorus and Sulfur
For HDEO (heavy duty diesel engine oil) SAPS are extremely effective for controlling wear, oxidation and limiting deposit formation. SAPS contribute to poisoning aftertreatment devices.
SAPS will not go away soon. They will reduce over time. Industry sees great potential for Mo based technologies to control oxidation, wear and deposit control
leading OEMs and oil companies surveyed – Low- /no SAPS oil topped the list of emerging technologies (in next 5-10 yrs)
Caterpillar Confidential Yellow Different lines of defense Coatings (Good Antiwear agent and Friction modifier) – Get worn away with sharp asperities
– Inert to additives
– No easy replenishment possible
ZDDP (Good Antiwear agent) – Needs activation so inadequate for cold start-up periods. – It forms hard antiwear protective films but increases friction.
– New environment regulation is forcing low or no P molecules.
Solid lubricant as particles (Good Antiwear and Friction modifier) – Micro particles settle in the oil.
– Nanoparticles available agglomerate, do not disperse.
Organic agents (Good Friction modifier) – Lack in required AW properties.
– Excess might cause undesirable acid formation.
Caterpillar Confidential Yellow Approach
As available
MS2 nano tube IF-MS2 (fullerene structure)
Conventional nanomaterials
Caterpillar Confidential Yellow Approach
Top down particle architecture
Multi-component
Surface stabilization and dispersion
Advanced 2-phase nanomaterial
MS2 nano tube IF-MS2 (fullerene structure)
Conventional nanomaterials
Caterpillar Confidential Yellow Chemo-mechanical Process
Dry Process Wet Process
Fractured small particles are Exfoliates planar layers aggregated due to increase in No size reduction surface energy Surface passivation
Caterpillar Confidential Yellow Hybrid Process (method of choice)
The hybrid milling process is a combination of dry milling and wet milling process
TEM graphs of hybrid milled MoS2 with dry milling step followed by oil milling step
Combination of high energy milling to decrease the particle size and use oil to prevent particles from fusing - will result in monodispersed particles
Caterpillar Confidential Yellow Technical Advantages
¾ Nanometric size: allows them to easily enter the surface asperity contact area
Caterpillar Confidential Yellow Technical Advantages
¾ Nanometric size: allows them to easily enter the surface asperity contact area
¾ Weak inter-planner bonds: delamination under high contact stress
Particles are not depleted in Transfer layer on asperity low load environment contact
Caterpillar Confidential Yellow Lubrication Mechanism
¾ Pressure sensitive architecture
¾ Exfoliation of external lamellar sheet
¾ Transfer of lamellar sheet (active component) to the contact zone
Undeformed Deformed Fractured (Hydrodynamic) (Mixed) (Boundary)
Caterpillar Confidential Yellow Tribology of nano-lubricants
Caterpillar Confidential Yellow 20 - 40% reduction in friction in BL regime
Evidence of MoS2 transfer layer on surface
Caterpillar Confidential Yellow BOR wear test; unidirectional
0.100
0.080 0.012 0.010 0.060 0.008
0.040 0.006 0.020 0.004 0.002 Mean Wear Vol (mm3) Vol Mean Wear Mean Coeff of friction 0.000 0.000 ) 2 1 ) ) ) C1 C C3 y C1 C2 C3 y 1 (H y 2(H C S2+C2(Hy) S2+C2 MoS2-hybrid o 2-comp (w/B Mo M MoS2+C2(H MoS2+
• Nano materials highly effective in reducing friction & wear
Caterpillar Confidential Yellow Block on Ring COF
0.080 and Wear Volume 0.070 0.060 50% reduction in COF 0.050 0.040 w/ nanomaterials 0.030 0.020 0.010 0.000
MoS Hybrid Milled in MoS2 Hybrid Milled in MoS2 com MoS2 Dry Milled 2 Base oil & ZDDP Oil ZDDP 0.09
0.08
Coefficient of Friction Mean Wear Volume, mm3 0.07
0.06
0.05
0.04
Nanomaterials Coefficient of Friction 0.03 Effective from the 0.02 1st cycle 0.01 0 100 300 500 700 900 1100 1300 1500 1700 Test Duration, Seconds
Base Oil MoS2 com MoS2 dry milled MoS2 Hybrid milled in oil Base oil & ZDDP MoS2 Hybrid milled in ZDDP
Caterpillar Confidential Yellow 1.00 0.90 0.80 0.70 0.60 50% reduction 0.50 0.40 0.30
Mean 4-ball WSD 4-ball Mean 0.20 0.10 0.00 Min BO K-B w/MoS2 B w/MoS2 Ag doped MoS2 Cat FZG Gear scuffing test with nano-technology Industry specified test ASTM D 4172
Base stock Base stock w/nano particle Load = 239.3 Nm Load = 304 Nm Scuffed No scuffing
Caterpillar Confidential Yellow KeyKey ElementsElements ofof nanonano--lubricationlubrication TechnologyTechnology LeadershipLeadership Control the Business Where it Counts • Engine • Aftertreatment • Transmission • Hydraulics • Undercarriage Control Core Competencies • Efficiency • Durability • Combustion/Emissions • Cooling
Caterpillar Confidential Yellow How will we win ?
9 Success through an integrated approach to lower SAPS and improve AT performance for engine systems solution
9 Deliver high efficiency lubrication with more power density and increase component life
9 Long term success through energy efficient nano- lubrication technology
Caterpillar Confidential Yellow Concluding Remarks
Technology Potential - Advanced lubrication for engine with potential to reduce friction and we ar characteristics and low SAPS Approach to Research - Novel nanomaterial technology with active particle architecture Technical Accomplishments – 9 A manufacture friendly process 9 Understand transfer layer lubrication mechanism 9 Particle stabilization process 9 Reduction in friction and wear (20 – 40%), Low SAPS Tech Transfer - Offers a nanomaterial technology for low friction / wear in engine with cost and scale-up analysis
Caterpillar Confidential Yellow Acknowledgement
DOE Support: DE-FC26-07NT43277
University of Arkansas – Prof. Ajay Malshe – Dr. Demytro Dimydov – Arpana Verma NanoMech LLC – Dr. Wenping Ziang Argonne National Lab – Dr. Ali Erdemir – Dr. Osman Eryilmaz
Caterpillar Confidential Yellow Thank you
Caterpillar Confidential Yellow