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Parameters Affecting the Functionality of Additives in Lubricated Contacts : Effect of Base Oil Polarity

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Parameters Affecting the Functionality of Additives in Lubricated Contacts : Effect of Base Oil Polarity ISSN: 1402-1757 ISBN 978-91-7439-XXX-X Se i listan och fyll i siffror där kryssen är LICENTIATE T H E SIS Aldara Naveira Suarez Affecting in Aldara the LubricatedAdditives Naveira Functionality Parameters of Contacts Parameters affecting the functionality of additives Department of Applied Physics and Mechanical Engineering in lubricated contacts Division of Machine Elements ParametersEffect Affecting of base oil the polarity Functionality ISSN: 1402-1757 ISBN 978-91-7439-077-3 of Additives in Lubricated Contacts Luleå University of Technology 2010 Effect of Base Oil Polarity Aldara Naveira Suarez Effect of Base Oil Polarity Aldara Naveira-Suarez Parameters affecting the functionality of additives in lubricated contacts Effect of base oil polarity Aldara Naveira-Suarez SKF Engineering and Research Centre Kelvinbaan 16, Nieuwegein THE NETHERLANDS Division of Machine Elements Luleå University of Technology SE-971 87 Luleå SWEDEN February 2010 Printed by Universitetstryckeriet, Luleå 2010 ISSN: 1402-1757 ISBN 978-91-7439-077-3 Luleå www.ltu.se Chemistry ought to be not for chemists alone Miguel de Unamuno, The tragic sense of life (1913) ABSTRACT Traditionally rolling contact fatigue observed in bearing field applications was subsurface initiated. However, despite the improvement of steel properties, some factors such as downsizing in bearing design, extreme loading of the bearings as well as demanding application conditions (start up-stop cycles) have led to an increase on the cases of surface damage related to surface initiated fatigue, that comes basically from surface distress. Possible causes leading to surface initiated fatigue are: material and surface properties, marginal lubrication and lubricant chemical composition. Lubricants are formulated products composed of base oil, and an additive package designed for a specific application. Extreme-pressure (EP) and antiwear (AW) additives are chemically active additives, they react with the steel surfaces in contact to form a protective additive- derived layer, thus reducing friction and controlling wear. However, certain EP/AW additives that increase the performance of other machine elements, such as gears, can be detrimental for the bearings running in the same lubrication environment. In order to identify the plausible mechanisms that govern the detrimental effect of EP/AW additives on bearing performance, it is necessary to study closely the interactions occurring in the system form by the base oil, the additives present and the steel surface, as well as the influence of operating conditions. The focus of the present work is to identify the parameters affecting the additive-derived layer formation, as it is directly related to the additive reactivity towards the surface, and the tribological properties of the layer, that will determine the tribological performance. Zinc dialkyldithiophosphate (ZDDP), and two low viscosity model oils with different polarity were selected. The influence of base oil polarity on the additive performance was studied in the nanoscale using Atomic Force Microscopy and the tribological performance was evaluated using a ball-on-disc test rig under mixed rolling-sliding conditions in the boundary lubrication regime. An in-situ interferometry technique was used to monitor the additive derived reaction layer formation, and the chemical composition, morphology and nanomechanical properties were studies using X-ray Photoelectron Spectroscopy, Atomic Force Microscopy and Nanoindentation respectively. i It was found that base oil polarity determines the transport of additives to the surface thereby controlling the maximum reaction layer thickness, friction and wear, as well as the morphology and nanomechanical properties of the additive-derived reaction layer. However the reaction layer chemical composition is not determined by the base oil polarity. Among the operating conditions, shear was identified as a fundamental parameter on the activation of additives on rubbing steel surfaces and the properties of the derived reaction layer. ii LIST OF PAPERS Paper A: The influence of base oil polarity on the tribological performance of zinc dialkyl dithiophosphate additives. A. Naveira-Suarez, M. Grahn, R. Pasaribu and R. Larsson (Submitted to Tribology International) Paper B: Effect of base oil polarity on micro and nano friction behaviour of base oil- ZDDP solutions. A. Tomala, A. Naveira-Suarez, I.C. Gebeshuber and R. Pasaribu (Tribology: Materials, surfaces and interfaces, 2009, In press) Paper C: The influence of slide-roll ratio on additive-derived reaction layer formation: Zinc dialkyl dithiophosphates A. Naveira-Suarez, M. Zaccheddu, A. Tomala, M. Grahn, R. Pasaribu and R. Larsson (To be submitted to Tribology Letters) iii ACKNOWLEDGEMENTS The work presented in this Licentiate thesis has been supported by the European Commission, through WEMESURF (Characterization of WEar MEchanisms and SURFace functionalities with regard to lifetime prediction and quality criteria – form micro to the nano range) research training network. I would like to thank my supervisors Prof. Roland Larsson and Dr. Rihard Pasaribu, for their great support and guidance, for sharing their knowledge with me and for their constant enthusiasm, encouragement and commitment to our work. My warmest thanks also to my colleagues at the Division of Machine Elements in Luleå University of Technology and at SKF Engineering and Research Centre, for creating an open and knowledgeable working environment. I would like to thank Mr Ralph Meeuwenoord for his great contribution to this work through his constant help in the tribological testing. Dr. Mattias Grahn and Fiona Elam have share many office hours with me and I must thank them for their patience. I specially want to thank Dr. Maurizio Zaccheddu, from SKF ERC and Agnieszka Tomala, from Vienna University of Technology, that have contributed greatly to this work, revealing some of the mysteries of Physics to me. Working with them is a privilege and a pleasure. I am especially grateful to Mr Hubert Koettrisch, for giving me the opportunity to join the team of the SKF Development Centre in Steyr, where I learned so much, and being an inspiring mentor to me. I would like to thank my family and friends for being always so close to me, despite the time and the distance. I deeply thank my parents, for their love and support, for teaching me the importance of ideas and always challenging me to be critical and to wonder, what it is so important in my work and in my life. iv CONTENTS ABSTRACT ......................................................................................... i LIST OF PAPERS..............................................................................iii ACKNOWLEDGEMENTS..................................................................iv 1. INTRODUCTION .......................................................................1 1.1. Tribology...................................................................................................1 1.1.1. Friction........................................................................................................1 1.1.2. Wear...........................................................................................................2 1.1.3. Lubrication..................................................................................................2 1.2. Lubricants.................................................................................................3 1.2.1. Lubricant additives: Extreme-pressure and antiwear additives ..................4 1.2.2. Organo-metallic compound type: Zinc dialkyl dithiophosphates.................7 1.3. Additive-derived layers............................................................................8 1.3.1. Additive-derived thermal layer....................................................................8 1.3.2. Additive-derived reaction layer ...................................................................9 1.4. Objectives ...............................................................................................11 2. MATERIALS AND METHODS ................................................15 2.1. Materials..................................................................................................15 2.1.1. Test samples ............................................................................................15 2.1.2. Base oils and additives.............................................................................16 2.2. Tribological testing ................................................................................17 2.2.1. Macro-tribological tests ............................................................................17 2.2.2. Nano-tribological tests..............................................................................19 2.3. Additive-derived reaction layer formation ...........................................21 2.4. Additive-derived reaction layer characterization ................................22 2.4.1. Scanning Electron Microscopy and Energy Dispersive X-ray Spectroscopy .................................................................................................................22 2.4.2. Atomic Force Microscopy .........................................................................23 2.4.3. Nanoindentation .......................................................................................23 2.4.4. X-ray Photoelectron Spectroscopy...........................................................23 3. RESULTS
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