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High-Tech Lubricants for a World in Transition

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  1. High-Tech Lubricants for a World in Transition • Engine Oils: • Zinc-Free Low SAPS Engine Oil Technology • Industrial Lubricants: • New Phenomena in Hydraulic Systems • Metalworking: • Replacement of Chlorinated Paraffins in Fine Blanking Operations • Cold Extrusion without applying Conversion Layers (Bondering) • Steel Cold Rolling: • Synthetic Cold Rolling Emulsions Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  2. Zn-Free Low SAPS Engine Oils:Formulation Technology Zn-free – Why? • Generally reduced ash formation -> better engine and AT devices cleanliness, higher efficiency for aged engines • Or: at equal ash formation -> more options for more important performance improvements: e. g. cleanliness, better wear protection, higher oxidation stability • Impact on morphology of ash (hard/soft): e. g. injection nozzles • Higher oxidation stability • Better anti-wear protection • Improvement of fuel economy • Minimizing chemical interactions with AT devices: e. g. DeNOx (Oxi-Cat, SCR) Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  3. Zn-Free Low SAPS Engine Oils: Impact on Morphology of Ash Sulfated/oxide ashes Sulfated/oxide ashes Ca-Sulfated/Oxide ashes are like “gypsum” soft Lead to less wear Ca/Zn-Sulfated/Oxide ashes are like “ore” hard Lead to more wear Ca-sulfated/oxide are softer and are removed “easier” during normal operation from injector nozzle, piston crown as well as from cylinder head than Zn-sulfate/oxide! Source: Gas engine oil field test with Ganymet Plus Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  4. Zn-Free Low SAPS Engine Oils: Viscosity Development at 100°C GFC-Test: 170°C Oil Temp. + 10 L/h Synthetic air Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  5. Zn-Free Low SAPS Engine Oils: TAN Development GFC-Test: 170°C Oil Temp. + 10 L/h Synthetic air Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  6. Zn-Free Low SAPS Engine Oils: Wear Control Optimization in RNT VW-TDI 85kW Pump-injector (PD) The activated tappet (56Co, 57Co) Online measurement Procedure (140 h): Breaking-in, Speed sequence, Polycyclic endurance run, Speed sequence Ash free (0 Zn) anti-wear protection works very effectively against high pressure wear during mixed friction Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  7. Zn-Free Low SAPS Engine Oils: Diesel Fuel Consumption Optimization Fuel consumption in M111FE Test (Reference RL 191 SAE 15W-40) Candidates Vis. grade HTHS Saving SAE mPas % Pkw HM A 10W-40 4,2 1,15 Containing Zinc Pkw HM B 5W-30 3,5 1,7 Containing Zinc Pkw HM C 0W-30 2,9 2,7 Containing Zinc LS 3 Pkw 5W-30 3,5 2,14 Zinc-free LS 6 Pkw 5W-30 3,05 2,62 Zinc-free LS 7 Pkw 0W-30 3,05 3,09 Zinc-free Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  8. Hydraulic Fluids: Filtration of Zn and Ash Free Hydraulic Fluids Multi-Pass Filterability Test Results for Different Zn Free Hydraulic Fluids:1 % water (8.7 l/min, 65°C, 100 bar, 15 l volume, 3µm/6µm)All Products fulfill DIN 51524-3 for HLP Hydraulic Fluids Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  9. Hydraulic Fluids: Electrostatic Charges - Zn containing - Zn free, high treat - Zn free, low treat- R + O Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  10. Hydraulic Fluids: Micro Scratching Zn free - high performance Zn free – low performance Pistons without Micro Scratches Pistons with Micro Scratches Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  11. Synthetic Cold Rolling Emulsions: Control of Particle Size Particle Size important to achieve high strength in the oil film. O/W emulsion W/O emulsion Particle Size important to keep oil consumption under control Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  12. Synthetic Cold Rolling Emulsions: Plate Out and Sheet Cleanliness Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  13. Synthetic Cold Rolling Emulsions: BAO Steel - Lubricity performance 8% higher production Forces 8 % lower Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  14. Sidmar BAF Scotch Tape 88,0 87,5 87,0 86,5 86,0 85,5 % Cleanliness HNX Scotch 85,0 H2 Scotch 84,5 84,0 83,5 83,0 82,5 2003 2004-2005 (w3) 2005 (w3-15) Synthetic Cold Rolling Emulsions: Sidmar - Cleanliness out of BAF Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  15. 12-13 % lower Rolling Forces in Stands 2 and 3 Synthetic Cold Rolling Emulsions: Sidmar - Lubricity performance - 3.5 % lower Energy Consumption Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  16. Chlorine-Free Fine Blanking:Pin-on-Disc: Chlorinated Oil radial force / normal force test time / s Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  17. Chlorine-Free Fine Blanking:Pin-on-Disc: Phosphorus-Sulfurous based Oil radial force / normal force test time / s Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  18. Chlorine-Free Fine Blanking:Pin-on-Disc: New Technology radial force / normal force test time / s Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  19. Chlorine-Free Fine Blanking:Comparison of Friction Traces Chlorin. oil New oil PEP/S oil Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  20. bonderized Oil 3.1 Oil 3.2 Oil 3.3 hydraulic oil Bonder-Free Cold Extrusion:Cup Drawing: Various Formulations press capacity / kN punch way / mm Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg

  21. Bonder-Free Cold Extrusion: No Bondering of Workpiece, New Lubricant and Tool Coating raw material formed with MoS2 (after cleaning) formed with oil 3.2 or 3..1 (without cleaning) Lubricants Russia 2007 Moscow, November 28, 2007 Dr. Georg Lingg