Nanotechnology for Lubricants to Improve Performance and … · 2014-01-29 · Nanotechnology for Lubricants to Improve Performance and Reliability of Army Systems Ken Eberts, Mohit

400 Apgar Drive – Suite E Somerset, NJ 08873 V: (732) 868-3141; F: -3143 www.neicorporation.com

October 15, 2013

Nanotechnology for

Lubricants to Improve

Performance and Reliability

of Army Systems

Ken Eberts, Mohit Jain

and Ganesh Skandan NEI Corporation – Somerset, NJ

and

Kristin B. Walker RAM & System Assessment Division, Redstone Arsenal

Program Sponsored by US Army SBIR Program

W31P4Q-11-C-0194

NEI Proprietary Information

About Us

• Founded in 1997

• Today, conducting R&D, manufacturing and marketing diverse Advanced Materials products

• Two facilities in New Jersey (15,000 ft2 space)

• Products sold under NANOMYTE® trademark

2

NEI building Shop floor Analytical Laboratory NEI building

400 E Apgar Drive 14C Worlds Fair Drive


Core Competency

• Nanotechnology expertise

– Bridge gap between basic and applied science by relating material properties to product performance

– Design and develop products (nanoparticles, nanocomposites and nanostructured materials)

• In-house capabilities to prove concept and demonstrate prototype in relevant environment

• Technology based, application driven, customer focused

Energy

Nanotechnology

Environmental Sustainability

3


• Advanced Protective Coatings • Energy Storage Materials • Environmental Nanomaterials • Nanoparticle Fluids

Nanomaterial Products

Nanomyte®

Series for:

4


Application Need

• Lubricants used in the Army’s ground and airborne vehicles • Lubricants with more efficient heat transfer can lead to:

- Reduced erosion of the gears - Reduced downtime - Reduced maintenance costs - Extended operation

• Engineer the lubricant (oil/grease) to enhance heat transfer properties

5

SBIR Data Rights Apply

Challenge

• Maximize Increase in Thermal Conductivity

• Minimize Increase in Viscosity

• Minimize Decrease in Heat Capacity

• Maintain or Improve Lubricity

h k 2/3 · Cp1/3 · 0.8 /0.467

Heat Transfer Correlation for Forced Convection in a Tube

h = heat transfer coefficient k = thermal conductivity of the fluid Cp = heat capacity ρ = density of the fluid η = viscosity of the fluid

6


Initial Work

• Base Fluid: – Valvoline Synpower 75W90 (VV975) Gear Oil

• Additives

– Commercially available, Micron-Scale Additive: Micro-1

– NEI-Synthesized, Nanostructured Additive: Nano-1

– Commercially available, Micron-Scale Additive: Micro-2

– NEI-Synthesized, Nanostructured Additive: Nano-2

7


Results: Comparison of Dispersion Stability

Over Time (without agitation)

Dispersions After ~1 Week

Micro-1 Nano-1

Nanostructure allows for highly stable dispersions

128

129

130

131

132

133

134

135

136

0 100 200 300 400

Time @ 40°C (hrs)

Th

erm

al

Co

nd

uc

tiv

ity

(m

W/m

-K)

Nano-1

Micro-1

Base Oil

8


Results: Viscosity Measurements at 40°C

86

88

90

92

94

96

98

100

102

0 10 20 30 40 50

Shear Rate (s-1

)

Vis

co

sit

y (

cP

)

Micro-1

Nano-1

Base Oil

Viscosity Reduction

More Newtonian Flow

9


120

125

130

135

140

145

150

Base Oil Nano-1 Nano-2

K (

mW

/m-K

)

+ 3%

+ 11%

Results: Comparison of Additive 1 and Additive 2 Thermal Conductivity of Dispersions in Oil at 40°C

10


Results: Effect of Dispersed Solids on Viscosity Index (VI)

ASTM D2270 - Kinematic Viscosity Calculated from Absolute Measurements

• Some reduction in VI for Nano-1

• Significant increase in VI for Nano-2

Potentially Allows for Wider Operating Temperature Range

120

130

140

150

160

170

180

Base Oil Nano-1 Nano-2

Vis

co

sit

y I

nd

ex

11


Scale-up and Independent Standardized Testing:

12

• Base Fluid: Valvoline Synpower VV975

“Base Oil”

• Base Fluid + Commercial Nano Additive:

“Commercial” (using recommended amount)

• Base Fluid + NEI Nano Additive:

“Nano-2”

SBIR Data Rights Apply 13

Results: Comparison of Oil Additives

Thermal Conductivity of Oil Dispersions at 40°C

120

125

130

135

140

145

Nano-2 Commercial Base Oil

The

rmal

Co

nd

uct

ivit

y (m

W/m

-K)


Results: ASTM D2983 Low Temperature Viscosity, -40°C

0

50

100

150

200

250

Base Oil Commercial Nano-2

Vis

cosi

ty (

Pa·

s)Fail

PassPass

http://www.synthetic-oil-tech.com /Gear%20Lube%20White%20Paper.pdf

http://www.synthetic-oil-tech.com/







Results: ASTM D2270 Viscosity Index

146

148

150

152

154

156

158

160


Vis

cosi

ty In

dex

(A

STM

D2

27

0)

http://www.flitalia.it/en/fl/manuale/en/trasm_0103.htm




Results: ASTM D4172 4 Ball Wear Test

Your Text

Scars form at contact points

0

0.2

0.4

0.6

0.8

1

1.2


Ave

rage

We

ar S

car

Dia

met

er

(mm

)


Extreme Pressure Testing: ASTM D2783 4 Ball EP Test ASTM D3733 Falex EP Test

Example:

Hypoid Gears

Pin

V-Block

ASTM D3733 Falex EP Test

ASTM D2783 4 Ball EP Test

Your Text









Results: ASTM D2783 4 Ball EP Test Wear Index and Weld Point

Weld

Your Text

High index indicates

reduced friction

0

10

20

30

40

50

60

70

80

90


We

ar In

dex

(A

STM

D2

78

3)

400lbs

500lbs500lbs Weld Point (lbs)









Results: ASTM D3733 Falex EP Test

Load to Failure

Load to failure (pin seizes)

0

500

1000

1500

2000

2500

3000

3500


AST

M D

32

33

B -

Failu

re L

oad

(lb

f)









Product Development and Demonstration

20

• Further Optimization of High Conductivity Additives

• Surface Functionalize for Dispersion in Aviation Oils • MIL-PRF-23699F Turbine Oil

• Aviation Gear Oil

• Performance Testing • In-House

• USC Apache Drivetrain Facility


115

120

125

130

135

140

145

150

155

Base Oil 1%Micro-3

0.5%Nano-3

1%Nano-3

The

rmal

Co

nd

uct

ivit

y (m

W/m

·K) 17%

Optimization of Thermal Conductivity

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128

130

132

134

136

138

140

0 20 40 60 80 100 120

The

rmal

Co

nd

uct

ivit

y (m

W/m

-K)

Time (hr)

Nano-5

Nano-6

Nano-7

Nano-8

High Stability

Optimization of Stability

22


8000RPM

Cool Air~23°C

0

2

4

6

8

10

Control Nano-2

Co

olin

g R

ate

(°C

/min

)

60% Faster Cooling

In-House Performance Testing

Oil Thermocouple

Shear Generator

70

75

80

85

45 46 47 48

Tem

pe

ratu

re (

°C)

Time (min)

Control Oil Temp

Nano-2 Oil Temp

23


Simulated Use Conditions USC Apache Tail Rotor Drivetrain Facility

24

Intermediate Gear Box (IGB)


Simulated Use Conditions Gearbox Operated Without Load

25

Average Gearbox Temperature

Cumulative Vibrational

Energy

0

50

100

150

200

250

0 500 1000 1500 2000

Tem

pe

ratu

re ( F

)

Time (sec)

AGL

Nano-4


Simulated Use Conditions Gearbox Operated WITH Load

26

Average Gearbox Temperature

0

50

100

150

200

250

300

0 100 200 300

Tem

pe

ratu

re (

°F)

Time (min)

370ft-lb

730ft-lb

980ft-lb

1220ft-lb AGL

Nano-4


Simulated Use Conditions Gearbox Operated WITH Load

27

Cumulative Vibrational

Energy

0 0.5 1 1.5 2 2.5

x 104

0

100

200

300

Frequency (HZ)

Am

plitu

de (

g)

Cumulative sum of enegies-after load step 3

Nano

AGL

0 0.5 1 1.5 2 2.5

x 104

0

100

200

300

Frequency (HZ)

Am

plitu

de (

g)

Cumulative sum of enegies-after load step 4

Nano

AGL


Future Development

28

Synthesize nanocomposite

particles

Characterize nanocomposite

particles

Incorporate nanocomposite

particles in fully formulated

lubricants

Incorporate nanocomposite

particles upstream during the lubricant

synthesis process

In-house laboratory testing

of lubricants

Testing under simulated use conditions

QUALIFICATION TESTING

Long-term & field testing

In-House and external used

lubricant analysis


Qualification Testing

29

• Viscosity Grade, per ASE and ISO

• Viscosity Index, ASTM D2270

• Pour Point, ASTM D97

• Flash Point, ASTM D92

• Oxidation Resistance, ASTM D943, D2272

• Rust Protection, ASTM D665

• Water Separability, ASTM D1401

• Copper Corrosion, ASTM D130

• Foam Test, ASTM D892

• FZG Scuffing, ASTM D5182, DIN 51534


Thank You

Documents

Nanotechnology for Lubricants to Improve Performance and … · 2014-01-29 · Nanotechnology for Lubricants to Improve Performance and Reliability of Army Systems Ken Eberts, Mohit