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377
The comparative tribological performance of a series of tapered bearings lubricated with a fully
formulated manual transmission fluid (MTF) and its PAO base oil was obtained using a KRL thrust bearing
tester. Bearing performance was based on the successful completion of an eight hour test procedure created for
the KRL tester. Optical microscopy was used to conduct textural analyses on the body contact areas of tested
rollers while X-ray photoelectron spectroscopy (XPS) depth profiles were used to collect surface film
composition at the previously mentioned contact area. The KRL results indicated that the MTF operated at lower
temperatures and performed better than the PAO. This difference was ascribed to the enhanced thermal stability
of the additive packages used in the fluid. The optical analyses detected a series of dark bands at the body
contact area of all tested rollers indicative of the presence of an EP/AW surface film. XPS depth profiles of the
base oil indicated that it generated a mixture of organic carbon and iron oxide which proved ineffective under
more severe test conditions. In contrast, the profile of the MTF included a mixture of carbonate, borate, sulfide,
phosphates and oxide throughout the film. Finally, the combination of thermal stability and EP/AW film
composition was attributed to the better performance of the MTF.
1. INTRODUCTION
Over the past decade, dedicated manual
transmission fluids have been developed to meet the
ever increasing requirements demanded by
equipment manufacturers (OEM) and government
legislations [1-2]. This process has involved the
careful balance between meeting these requirements
and the cost of development.
The first sets of costs are associated with the
selection of the base oil. This step is predicated by
the need for fuel efficiency, reduced oil capacity,
shear stability, thermal and oxidative stability.
These requirements have eliminated most of the base
stocks except those with high viscosity indices
(HVI) [3-4.]. Even with these requirements, their
high prices have somewhat limited their usage. But,
cost balance has been improving with reports of 5 to
10~
reductions in operating temperatures of
transmissions lubricated with such base stocks [3].
Other requirements such as load carrying capacity,
wear, pitting, synchromesh compatibility and
corrosion resistance have been found to depend on
378
also increased the ability to correlate tribological
responses with the additive effects in the fluid and
surfaces of the tested components [9-13].
The aim of this paper is to present the use of
this approach for the development of an MTF. First,
a KRL bearing shear stability tester was selected for
the performance testing. [8-9]. Field experience had
shown that this method showed good correlation
with actual transmission tests [1]. With additional
modification of the rig, thermal stability and
frictional torque were also monitored and recorded.
Finally, surface analysis was used to verify that
typical tribological films could be generated with
this approach.
2. E X P E R I M E N T A L
A PAO and its fully formulated MTF
analogue used for this study were selected from a
multi blend lubricant matrix. They were designated
A and B, respectively. A was selected because of its
viscosity, HVI and shear stability [3]. B was then
formulated with a series of additive packages
designed to reduce operating temperatures, promote
surface film formation, and passivate non steel based
components. The relevant information for the two
fluids was listed in Table 1.
All tribological tests were conducted with a
Shell four-ball tester modified in accordance to the
DIN 51350 Part 6 procedure referred to as a KRL
thrust-bearing rig (8-9). All tests were conducted
with a 40mm bore tapered bearing, a 35ml lubricant
volume and a four step two cycle 8H tribological
sequence. In Step 1 of the KRL test, the load was
set at the maximum value of 5.825KN to 350rpm for
PAO
Amine Phosphate AW; Sulfur EP-AW
Borated Dispersant; RI-Demulsifier
Amine Anti Oxidant, Foam Inhibitor; Cu Inhibitor
VI
Viscosity (cSt)
40~
44
48.0
100~
8.0
7.87
136 .......
137
379
Figure 1. Tribological test procedure.
Sequence
KRLTest
3500
"r
e
"I~
_~
Cycle 1
I~~
T
t Step3
-!
Cycle 2 .................... ~
~I
0~--~-Speed._
Load
Step3
.........................................
2000 I
~oo
. . . . . . . . . . . . . . . . . . . . .
3000 ...............
Ii
"-'t= 2 5 0 0
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
~!
..........................
I000
l l l I. I~-I~III-I
I11 ~"ii
--~'~i "~III
..
500
t~
~I llllll Ill
Step
r~
r~
..................................................................
r~
v~
c~
380
Figure 2. Temperature traces.
other.
The observed behavior for B during Step 2
was very different and was called regime 2. In this
regime, the thermal responses nearly doubled but
equilibrated during the duration of the speed
increase. The ability of the fluid to dissipate this
thermal input was obviously related to its shear
stability and effectiveness of the additive
components in the formulation. The maximum
381
recorded temperature for both tests during that
operating time was 95~
Small spikes followed by
sharp decrease were also observed for the torque
responses. These spikes coincided with the speed
increase and were related to temporary reductions in
the fluid films due to the induced high shear forces.
However, unlike in A, the values decreased very
quickly. These sharp decreases were explained by
the formation of an effective surface AW film that
further helped with the reduction of the heat input
[14-15]. The observed stabilization was therefore a
combination of fluid thermal stability and AW film
formation. This combination must have promoted
the transition from temporary operation in the
mixed to true operation in the EHD lubrication
regime. In this regime, torque and temperature
were out of phase with each other. Interestingly,
regime 2 like behavior was also observed for Step 3
of the test cycle. The temperature similarly doubled
and gradually equilibrated to a maximum value
around 130~ for both tests. Similar to Step 2, the
torque spikes were related to the speed increase and
their reduction to the formation of the AW film.
Thus, shear stability, additive composition and AW
film formation were again responsible for this
excellent tribological behavior. However, it was
not clear whether the same type of AW surface
films were generated since time dependent studies
were not undertaken.
Table 2. Summary of tribological behaviors.
Regimes
Test Sequence
T&M
2&3
'4
Lubrication Regime
Out of phase
Boundary to EHD
Out of phase
EHD
In Phase
Out of PhaSe
382
..........................
x ............
x .....
. . . . . . . . . . . . . . . . . . . . . .
'%.
\\
\"\ ~\.
N
L-
..,.=-:
,4.
r:l
1 o
121
loo
21~
~ r'Jl~
r-j
L:5~:~u-H~_r
O~_p-tl
4-
-- Clt'J
383
2p312
,:/"
CIg
Fe2p 2p~2/ ~.
,t
t
!i
1--
'
03 m
'11!5
L
~'-'-'~-----~,
I D o
--
.--o
~..,
'%,~
"\,.
,-..
",.,,.
. . . .
'----...
s--
..
"-% .......
=;oo
1 iOR:lO
15z:x3
"~:,u~k=r
13~plh
~ll:X3
384
Figure 8. C1 s and Fe2p3 binding energies for A.
Fe2p
9 I~
Cls
2p3/2
Z ~I~
2pl/Z
. . . .
~",,
-I
-n
.-2o
-I~
'le"
--- ~ L
.~
WO-
,,,.,....
L aa-i--
/,
r,~
'-'Sputter Dept'h'*~)
385
Figure 10. B l s, S2p and P2p binding energies for B.
/
'~~
,'. ,,' ,
< v
2eo
~'""
,.
"
i'
'I"
"~(~',.
".-.
!'90
;"
"," ..
'~
to/
1r
8imin 9 ~r~y
" '
. '
,,
tao--
1r
130 1
levl
Cls
"'<
t"~. ~
z-
t1
"-
1--
--..~-..._~_.-~..._~ . ~ >
/
,/
....
'I 711:! tt
/-
-,,
o
.--.111
-~o
.-
-z~
-~o
/-
-I s
.t-
-to
.i
-.on
386
Table 3. SummarT of the XPS analysis.
Samples
Elements
Binding Energies
(eV)
New
Cls
285.2
282.3
Fe2p3/2
709
707.3
A
Cls
286.4
285-282
Fe2p3/2
710
710-707
707
B
Cls
288.8
285.0
Bls
192.03
$2p3/2
162.61
P2p3/2
133.2
Fe2P3/2
709.9-706.8
706.8
Sputter Cycle
Thickness
Compound Type
0-15
15-30
0-15
15-70
0-120
120-900
0-40
40-900
0-40
40-2500
0-40
40-1200
1200-2500
,,,
...
0-6
6-70
0-30
30-55
55-70
0-4
4-40
0-24
0-24
0-24
0-24
24-40
0-30
30-2000
0-500
0-500
0-500
0-500
500-2000
REFERENCES
1.
2.
3.
4.
5.
6.
7.
(A)
8.
9.
10.
11.
12.
13.
387
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Photoelectron Spectroscopic Study of
Surfaces
Tested
with
Organosulfur
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Lubrication
with
Tricresylphosphate (TCP). Importance in
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(1982).
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