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SYSTEMS, STRATEGIES & RESEARCH FOR LUBRICATION PROFESSIONALS AN PUBLICATION | AUGUST 2017
TLT
T R I B O LO G Y &
LU B R I C AT I O N
T E C H N O LO G Y
13 YEARS
of publishing excellence
What can it do?

How accurate is it?
What you need to get started
(Hint: its not a degree in statistics)
+ 3D Printing: The next

Industrial Revolution?
+ Fighting Foam:
Q&A with Michael Stapels
+ Einstein, STLE & you
+ New economic models drive

Latin America & the Caribbean
+ Selecting the right plane bearing
+ W. Edwards Deming:
14 Points for Management
+ CH;FFSSCHA=;LM
Digital TLT: Sponsored this month by Acme-Hardesty and Temix at www.stle.org.

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Contents TLT / AUGUST 2017 / VOLUME 73 / NO. 8
16 22 28
FEATURES
MARKET TRENDS WEBINARS 2018 TRIBOLOGY FRONTIERS CONFERENCE
16 Lubricant growth in Latin 32 Selecting the right 50 2016 Abstract: Shining a

America and the Caribbean plane bearings light on the tribological
New economic models are They do jobs other bearings rehydration of cartilage
driving demand with Brazil, cant, but understanding their The 2018 TFC Planning Committee
Mexico, Argentina and Chile heat, friction and material is partnering with TLT to present
leading the way. properties is critical. a new feature2016 TFC
By Sharbel Luzuriaga By Debbie Sniderman Highlights.
By Axel C. Moore,
Brian T. Graham, Chris Price
20 MINUTES WITH FEATURE ARTICLE
and David L. Burris
22 Michael Stapels 40 Moneyball for uid
This research chemist with Kao development
PEER-REVIEWED PAPER (EDITORS CHOICE)
Chemicals GmbH discusses foam Statistical design of experiments
countermeasures and why he couples a numbers-based 52 Optimization of Mechanism
recommends ethercarboxylic approach with practical of Boundary Lubrication in
acids for the formulation of experience to extract the Fully Formulated Commercial
metalworking uids. most information from the Engine Oil Using Design of
fewest experiments. Experiment
By Rachel Fowler
By Dr. Nancy McGuire By Gabi N. Nehme and
Micheline Dib
LUBRICATION FUNDAMENTALS
28 Words mean things

Especially when it comes to
3D printing, which could be
on the verge of ushering in a 40
third Industrial Revolution.
By Dr. Robert M. Gresham
W W W. ST L E .O RG T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY AUGUST 2017 1

Contents
DEPARTMENTS EDITOR
Evan Zabawski, CLS
TestOil
10 Tech Beat Calgary, Alberta, Canada
ezabawski@testoil.com
Printing batteries;
photoelectrochemical PUBLISHER/ SENIOR FEATURE WRITER
generation of hydrogen over EDITOR-IN-CHIEF Jeanna Van Rensselar
Thomas T. Astrene
100% quantum efciency; tastrene@stle.org CONTRIBUTING EDITORS
hexagonal close-packed Stuart F. Brown
MANAGING EDITOR Dr. Neil Canter
high-entropy alloy. Rachel Fowler Dr. Robert M. Gresham
rfowler@stle.org Dr. Nancy McGuire
By Dr. Neil Canter Debbie Sniderman
74 Newsmakers 6 CIRCULATION
COORDINATORS
ADVERTISING SALES
Tracy Nicholas VanEe
This months newsmakers Myrna Scott Phone: (630) 922-3459
Judy Enblom Fax: (630) 904-4563
include Sea-Land Chemical, Nadine Sanchez tnicholas@stle.org
Spectro Scientic, SONGWON COLUMNS (847) 825-5536
DESIGN/PRODUCTION
Industrial Co., The Schaefer Joe Ruck
Group and more. 4 Presidents Report
The Jeanie McCoy TECHNICAL EDITORS
84 Sounding Board Scholarship Award Mikey Benes Dr. Peter Lee
Baker Hughes Southwest Research
Which lubricant component will Institute
be most critical to meeting your 6 From the Editor Dr. John Bomidi
Baker Hughes David Lindsay
future challenges? Silk round ball batch Michelle Brakke
Afton Chemical Corp.
Lubrication Dr. James MacNeil
Technologies Inc. Qualice
90 Advertisers Index 8 Headquarters Report
Patrick Brutto Shawn McCarthy
Albert Einsteinyoung ANGUS Chemical Co. Ocean State Oil
92 Resources professional Neil Buchanan Dr. Hamidreza Mohseni
HollyFrontier Corp./ Bosch Brake Components
Keep up to date with the latest Petro-Canada America
technical literature available in 94 Cutting Edge Lubricants Inc. Dr. Mary Moon
Zeroing in on ZDDP Presque Isle
print and online. Bridget Dubbert Innovations
tribolm growth Engineered Lubricants
Jason Papacek
Dr. Monica A. Ford
Calumet Specialty
Ingevity
96 Automotive Tribology Products Partners, L.P.
Dr. Hamed Ghaednia
The future of ying is near Ford Motor Co. Dr. Jonathan Reeds
Precision Polyolens
Dr. Arnab Ghosh
Sentient Science Joe Schultz
The Lubrizol Corp.
Dr. Michael Glasgow
Afton Chemical Corp. Dr. Don Smolenski
Evonik Oil Additives USA
Dr. Martin Greaves
The Dow Chemical Co. Tom Triola
The Timken Co.
This Months Factoids Tyler Housel
Lexolube Div. Zschimmer Dr. Paula Vettel
W. Edwards Deming: 14 Points for Management & Schwarz Novvi, LLC
Dr. Robert Jackson Dr. Nick Weinzapfel
Auburn University Sentient Science
Copyright 2017 Society of Tribologists and Lubrication Engineers. All Rights Reserved. TRIBOLOGY AND LUBRICATION TECHNOLOGY (USPS 865740)
TLT magazine is owned and published in print and electronically by the Society of Tribologists and Lubrication Engineers (STLE). Vol. 73, Number 8, (ISSN-1545-858), is published monthly
The views set forth in this magazine are those of the authors and not necessarily the views of STLE. Material from TLT magazine by the Society of Tribologists and Lubrication Engineers,
may be reproduced only with written permission from STLE. TLT magazine assumes no liability or responsibility for any 840 Busse Hwy, Park Ridge, IL 60068-2376. Periodicals
inaccurate, delayed or incomplete information. For more information, contact us at TLT@stle.org. Postage is Paid at Park Ridge, IL and at additional mailing
Subscription and Single Copies: Current volume single copies are $25 (not including shipping and handling). Annual subscription ofces. POSTMASTER: Send address changes to Tribology
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must be by international money order or bank draft drawn on U.S. bank. IL 60068-2376.
Front Cover Can Stock Photo / maxmitzu
2 AUGUST 2017 T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY W W W. ST L E .O RG

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PRESIDENTS REPORT
Michael Anderson
The Jeanie McCoy Scholarship Award

STLE has created a new program to assist
young women pursuing careers in tribology.
AN AREA THAT HAS ALWAYS McCoy Scholarship Award, will recog-
BEEN NEAR AND DEAR TO ME is nize and support outstanding young
the fostering of our young people women studying to pursue a career
to explore and pursue careers in in tribology (see Page 5).
the eld of tribology. In fact, one Having known Jeanie for almost
of the rst committees on which I 40 years, I can attest to her dedica-
served the Chicago Section (1982- tion in all the fundamental goals of
1984) was in a newly established promoting tribology and STLE. Re-
program called Careers in Lubrica- cently STLE Executive Director Ed
tion. This was a small group of Salek and I met with Jeanie to pres-
Chicago Section members who ent the plaque recognizing the es-
visited universities to meet with tablishment of the scholarship
undergraduate and graduate stu- named after her. Presenting the
dents and talk about a little known plaque to Jeanie in person will cer-
eld called tribology. tainly be one of the highlights of my
During this time we had the term as STLE president.
pleasure of establishing two stu- With the ever-growing promo-
On June 21 STLE Executive Director Ed Salek and I
dent chapters. The rst was at Pur- tion of tribology, the future looks
presented a plaque to Life Member Jeanie McCoy
due University Calumet and the bright for young people entering our
recognizing the new scholarship named in her honor
other at Northwestern University. It for women pursuing careers in tribology. industry. And STLE is one of the lead-
was really a great opportunity to ing reasons this eld is growing.
see the excitement in these young STLE also assists the local sec-
people as they participated in the tions scholarship programs by
Chicago Section by attending local meetings E. Richard Booser Scholarship for under- matching the local sections awards up to a
and promoting tribology at their own cam- graduate students engaged in the study total of $15,000. STLE promotes student work
puses with the assistance of Chicago Section of tribology. through the poster sessions at the annual
members. Elmer E. Klaus Fellowship for graduate meeting as well. This, plus the above men-
One of STLEs primary and ongoing goals students pursuing a career in the study of tioned scholarship awards, brings the yearly
is education. With this in mind, STLE is always tribology. amount of STLE scholarship funding to well
looking for ways to promote tribology and the over $50,000. STLE is living up to its goal in
study of related sciences within academia. Early Careerist Award for recent gradu- education through these funding programs in
Today STLE has active student sections at ates who are making positive advances in order to challenge students to excel in devel-
University of Monterrey (Mexico), Auburn Uni- the eld of tribology. oping their knowledge in our eld.
versity, University of Texas (two chapters), The rst two of these awards were named So I openly encourage you to support
North Texas and Arlington (combined) and in honor of STLE members who, throughout young people and the promotion of knowl-
Houston. As the number of programs increas- their careers, helped enhance the eld of tribol- edge through education in tribology to keep
es within the colleges and universities, there ogy through education, whether in academia the world moving more efciently.
is an ever-growing need to recognize and or industry. This year we are recognizing an-
encourage these students and others to pur- other outstanding STLE member by establishing
sue careers in the eld of tribology and lubri- a scholarship award named in her honor. Mike Anderson is Area Manager
cation sciences. Jeanie McCoy of Jeanie McCoy Technolo- Asia Pacic/Latin America for
Currently STLE offers three scholarship gies (retired) has spent a lifetime promoting Falex Corp. in Sugar Grove, Ill.
awards for students pursuing the study of the science of tribology and lubrication engi- You can reach him at
tribology and/or a related science eld: neering. STLEs newest scholarship, the Jeanie manderson@falex.com.
4 William Edwards Demingknown to the world as W. Edwards Demingwas born in Sioux City, Iowa, Oct. 14, 1900.
STLE creates Jeanie McCoy
Scholarship Award
New honor benets female college and high school students
pursuing careers in tribology.
STLEs board of directors has developed a scholarship named after STLE

Life Member Jeanie S. McCoy of Jeanie McCoy Technologies (retired).
The new award, the Jeanie McCoy Scholarship Award, will aid female
college and high school students pursuing careers in tribology.
The STLE board approved the award at the societys 72nd Annual
Meeting & Exhibition last May in Atlanta. The scholarship will be pre-
sented for the rst time during STLEs 73rd Annual Meeting next year in
Minneapolis, Minn.
The scholarships requirements were developed with the assistance
of STLE Past President Dr. Maureen Hunter of King Industries and state
that the recipient must be a female matriculating student pursuing an
education or career in the eld of tribology and enrolled as one of the
following:
a senior in high school with plans to pursue an education in

the eld of tribology
an undergraduate student pursuing a degree with tribology
science experience
a graduate student pursuing a degree in the tribology sciences.
McCoy has been a member of STLE for more than 65 years, joining in
the early 1950s when the lubrication industry was clearly male dominated.
While STLEs historical records cannot verify that McCoy was the societys
rst woman member, she was certainly one of the rst, one of the most
active and one of the longest members of STLE.
McCoy began her career working for The Hodson Oil Co., whose
president, Walter Hodson, is credited as the person most responsible In 1952 Jeanie applied for membership in the American Society of
for starting STLE in 1944. In 1952 she began a long career with Interna- Lubrication Engineers (ASLE), which became STLE in 1987. She served as
tional Harvester Co. (IHC), retiring in 1985. At that time she began a editor of Lubrication Engineering, ASLEs original technical magazine
consulting company, Jeanie McCoy Technologies, focusing on the prop- that eventually became TLT, for more than two decades. In 1989 she
er application and maintenance of metalworking uids. became the rst woman STLE member to be elevated to the grade of
McCoys technical expertise has helped many organizations improve Fellow, STLEs highest honor for technical excellence and presence in
the efciency of their operations and extend the life of their metalworking the eld of tribology and lubrication engineering.
uids by developing technologies to control bacterial growth. One of her In 1991 the society presented McCoy with the P.M. Ku Meritorious Award
rst assignments at IHC was addressing bacterial growth at one of the for tirelessly serving STLE and its local sections throughout the U.S.,
companys manufacturing plants that was so bad the city forced the plant Canada and the world with her many education courses and speaking
to shut down. McCoy developed a chemistry to reduce the contamination engagements on metalworking uid maintenance. In 2000, to recognize
from bacteria growth that solved the immediate issue. She then instituted her outstanding lifetime contributions to the promotion of tribology and
a maintenance program to prevent bacterial growth by regularly inspect- lubricants, she received the International Award, STLEs highest honor, and
ing the various uids used at all IHC manufacturing facilities. later was named a Life Member of the society.
Demings theories on quality control in mass production would revolutionize the world and rebuild national economies. 5
FROM THE EDITOR
Evan Zabawski
Silk round ball patch

Hollywood fact or ction?
TIGHT WEAVE? SILK. ANOTHER 40
YARDS. This exchange in the lm The Last
of the Mohicans has always caught my inter-
est. It takes place between a member of the
colonial militia and the main character, Hawk-
eye, regarding the type of material Hawkeye is
using as a patch when he loads his long rie
20th Century Fox Film Corporation

in readiness for a long-distance shot.
I had always presumed that a smoother
fabric would result in less frictional loss as
the shot traveled down the barrel, thereby
resulting in further travel. After revisiting
the lm as it nears its 25th anniversary this
The speed of the ball as it exits the barrel (muzzle velocity) is inuenced by both the
month, I thought I would look a little further
charge and the patch.
into the validity of Hawkeyes remark, which
does not appear in the text of the original
book by James Fenimore Cooper.
To begin with, the process of loading regarding patch material selection. It says, which is a tight weave linen used to prevent
a intlock long rie entails standing the Place your patch for which oiled canvas down feathers from poking through the fabric,
rie upright, pouring in a measured powder or silk will answer, but the nest kid leather, has a common thickness of .015 inches but
charge, tapping the rie to help settle the delicately greased, is the best article square may range from .010 to .020 inches.
powder, placing a lubricated cloth patch on on the nozzle. Silk has a very similar thickness but a
the end of the barrel, centering the round Oiled canvas is simply another term for higher tensile strength, which may have
ball (shot) on the patch, starting the bullet waxed cotton, which is cotton impregnated greater resilience in preserving the seal
down using a bullet starter, ramming the bul- with beeswax or a parafn-based wax. Other around the ball as it travels the length of the
let down the bore (using a ramrod) until it contemporary documents reference patch barrel. This is reinforced by Henry Wilkinson
contacts the charge, priming the rie and, lubricant as commonly being rendered hog (of Wilkinson Sword fame, a company now
nally, cocking the hammer. or sheep tallow, frequently mixed with bees- known for making shaving razors) when he
The speed of the ball as it exits the bar- wax, suggesting the chief difference between wrote in his 1841 Engines of War, I have found
rel (muzzle velocity) is inuenced by both an oiled canvas patch and a silk patch is the silk patches the best for very ne shooting,
the charge and the patch, and this speed material itself. as they admit of using a larger ball than any
ultimately affects the distance and accu- The rationale for even using a patch at other material without tearing or cutting, in
racy of the shot. One other factor that only all is not to separate the ball from the pow- forcing down the barrel.
affects the accuracy is the riing; these are der charge, as it is in pellet-loaded ries, but At least I have a better understanding of
the helical grooves that impart a spin to the rather to create a gas-tight seal around the the logic and that it is not a friction-related
ball. Pennsylvania ries, like Hawkeyes, typi- ball to transfer as much of the energy from decision, but hard data could prove if it actu-
cally had a very slow twist, being less than the explosion as possible without cutting the ally yields greater distance.
one complete turn over the nearly four-foot ball and leaving wear debris in the barrel.
length of the barrel, suggesting speed is re- Given a .50-inch bore using a ball measuring
quired for a fast spin. .489-.491 inches, it leaves .0045-.0055 inches
The use of silk patches is conrmed in of a gap all the way around the ball. However, Evan Zabawski, CLS, is the
Holdens Dollar Magazine, Vol. VI, No. III, from once the .01-inch grooves are factored in as senior technical advisor for
September 1850 and contains an article titled well, the ideal material thickness becomes TestOil in Calgary, Alberta,
Three Chapters for Young Sportsmen, written .015 inches .001 inches, which is about the Canada. You can reach him at
by Charley Chase, which provides guidance thickness of card stock paper. Pillow ticking, ezabawski@testoil.com.

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HEADQUARTERS REPORT
Edward P. Salek, CAE / Executive Director
Albert Einsteinyoung professional

The edgling genius needed a break. He got it thanks to a reluctant
mentor and a lecture at an association conference.
M Y SUMMER READING LIST INCLUDED

Einstein: His Life and Universe, a biogra-
of people who make decisions that affect
your future. It was true in 1909, apparently,
phy written in 2007 by Walter Isaacson, and it certainly is true at STLE in 2017.
CEO of The Aspen Institute and a former For those more experienced people
head of CNN. Hes written a number of who are on the other side of the equation,
other biographies, including a more re- take the time and have the patience to be
cent best seller about Steve Jobs. This a supportive mentor. Consider how differ-
earlier work by Isaacson came to my at- ent the world might be if professor Klein-
tention after watching an episode of the er did not have a change of heart about
National Geographic network television Einstein after sitting in on his disorga-
series titled Genius, which was based on nized classroom lecture.
the book. Finally, be persistent. According to
In one of the opening chapters, Isaa- Isaacson, Kleiners criticism stung Einstein
cson describes Einsteins struggles as a and caused him to take the Zurich society
young professional in Switzerland during lecture much more seriously than the
the rst decade of the 20th Century. Ein- classroom lecture in Bern. Theres much to
stein already had achieved a certain be said for requesting a second chance and
The principle that launched Einsteins career
prominence by publishing more than 20 in 1909 is still relevant for STLE members then making the most of the opportunity
revolutionary papers that had been no- in 2017. as Einstein did in this instance.
ticed by the giants in the eld of theo- Finally, a thought that applies to many
retical physics. His list of admirers in- situations: Judge people by their poten-
cluded Max Planck (the originator of tial, not by their background, appearance
quantum theory) and Arnold Sommerfeld or current position. In 1909 Einstein was a
(famous in the lubrication world for the num- guest instructor at the University of Bern. He patent examiner with limited teaching skills,
ber that bears his name). informed Einstein that he was hesitant to early signs of his trademark unruly appear-
Somewhat surprisingly, Einsteins scien- nominate him for a faculty position in Zurich. ance and an amazing capability to conduct
tic research was basically being done in his But Einstein persisted and delivered a thought experiments that would unlock the
spare time. To earn a living, he was working February 1909 lecture to the Zurich Physics secrets of our universe. Try not to ignore sub-
as a patent examiner in Bern, Switzerland. His Society that turned his reluctant mentor into stance because of the supercial.
repeated efforts to join the academic world an advocate. Einstein was recommended for If youre looking for a good book to close
had not been successful. At one point he even a faculty position, approved by a secret vote out the summer, I can recommend Einstein:
applied for a job teaching high school math- of the Zurich faculty and joined the university His Life and Universe by Walter Isaacson. And,
ematics but failed to make it into the top tier as a 30-year-old junior professor in October if youre searching for a place to build your
among 21 candidates for the position. 1909. By 1921 he would receive the Nobel Prize career, make STLE your professional home.
Einsteins luck changed thanks to assis- in Physics. His remarkable achievements con-
tance by Alfred Kleiner, a professor of physics tinued for the next 35 years until his death in
at the University of Zurich, who had helped April 1955.
Einstein get his doctorate in 1905. Although What lessons can be learned from this
eager to assist his protg, Kleiner encoun- sliver of history? For anyone starting a career, You can reach Certied
tered some reservations after sitting through the message is that associations are a place Association Executive Ed Salek
a clumsy lecture Einstein gave as a sort of where you can bring your skills to the attention at esalek@stle.org.
8 Deming is credited for the Japanese Industrial Miracle where Japan not only recovered from the ruin of WWII but quickly emerged as a world economic leader.
TECH BEAT
Dr. Neil Canter / Contributing Editor
Printing batteries
A 2,000-year-old technique can place a stretchable battery
on fabrics or on materials that adhere to the skin.
FINDING WAYS TO MAKE SMALL ELECTRON- The value of this nding is that the performance. It also is expensive to
ICS more user friendly and exible con- device was comfortable for the user in prepare this battery.
tinues to be a research objective. Har- contrast to conventional batteries that A promising way to prepare a
nessing these devices can be useful in have stiff surfaces and are not compat- stretchable battery is through a tech-
a wide range of applications, including ible for use with individuals, particu- nique known as screen printing. This is
those related to medical sensors, textile larly during periods of exercise. a method that has been used for nearly
optics and soft robotics. The tattoo was developed by the 2,000 years and involves applying an
In a previous TLT article, a exible research group of Joseph Wang, Dis- ink to a substrate through the use of a
biofuel cell in the form of a temporary tinguished Professor and chair of the mesh stencil which also is known as a
skin tattoo was developed.1 The fuel nanoengineering department at the screen. Screen printing is used in many
used by this device was lactate acces- University of California San Diego in applications such as applying designs
sible from human sweat found on the La Jolla, Calif. Rajan Kumar, graduate to T-shirts.
skin. In testing, the biofuel cell was able student working with professor Wang,
to maintain power output at 50% of its points out the problems in trying to use
original value for a four-week period. conventional batteries in small wear-
The researchers developed
able electronics. He says, Batteries are
a very appealing option for use in small an ink containing a zinc-silver
electronics, but their use is limited be- oxide that was mixed with a
cause they are rigid and bulky. Exam-
KEY CO
CONCEPTS
C S ples include coin cells, button batteries
binder consisting of a
and pouch batteries. polystyrene-polyisoprene-
Stretchable batteries that can
Several approaches have been polystyrene (SIS) block
be used in exible electronics taken to develop stretchable batter-
have been prepared
prepar d by ies that would be better designed for copolymer.
appl
applying
p ng an ink too a substrate
ssubst
b t ate
tee use in exible electronics. Kumar says,
such as a T-shirt through a Two of the approaches used to prepare
technique
technique
q known as screen stretchable batteries are known as de- Kumar and his colleagues have now
terministic composite and the random successfully used screen printing to
printing.
composite fabrication. The determinis- place a stretchable battery on fabrics
A new ink binder known as SIS tic battery is arranged in a coil that can or on materials that adhere to the skin.
show exibility when uncoiled. Limi-
works well because it combines
co b ess STYRENE ISOPRENE
tations for this technique include the
elasticity
l t ty withth hardness.
h d expense of fabricating the battery and BLOCK COPOLYMERS
also the loss of effective operating area. The researchers developed an ink con-
During
Duringg testing
t t g thee battery
b ttery was
waas
In a random battery, exible elastomers taining a zinc-silver oxide that was
stt etched
stretched
t h d too an elongation
elongg t n of are combined with traditional battery mixed with a binder consisting of a
1,300%
300%% without
th t suffering
fffering a loss
loosss powders. This helps with stretchabil- polystyrene-polyisoprene-polystyrene
in performance. ity, but the non-conductive properties (SIS) block copolymer. Kumar says,
of the elastomer lead to diminished We initially worked with a zinc-based

Figure 1 | A stretchable zinc-based battery was screen printed as the word NANO on a white T-shirt and is powering a lit green LED.
(Figure courtesy of the University of California San Diego.)
battery because it has a high charge to sit in storage for a week without de- timeframe. A factor that may help the
density and is more stable than lith- stabilizing. A minimal amount of SIS researchers with durability is that most
ium batteries but is not rechargeable. also can be used. printed batteries may not need to be
The problem with lithium batteries is To illustrate the performance of stretched by 100%. Kumar says, We
that this type of processing may lead the stretchable battery, the research- believe that stretching to 50% may be
them to catch on re. We feel that ers screen printed it onto a stretch- adequate for most applications.
screen printing can be done with any able textile as shown in Figure 1. Then The stretchable battery prepared
type of battery. they stretched, crushed and indented by screen printing exhibits the highest
One of the unique aspects of this the textile multiple times. The screen- capacity and discharge current density
battery is the use of SIS as a new elas- printed battery was stretched to an to date. Additional information can be
tic binder. The researchers evaluated a elongation of 1,300% without losing found in a recent article2 or by contact-
series of polymers but could not iden- any performance. Kumar says, One ing Kumar at rak010@ucsd.edu.
tify a suitable one due to a number of analysis tool used was to evaluate the
problems. Kumar says, We looked at strain the stretchable battery was sub-
the top carbon-based binders, but they jected to in real time.
REFERENCES
exhibited bad performance in part be- A major problem seen by research-
1. Canter, N. (2014), A new type of
cause of poor elasticity. The unique ers is the formation of cracks that oc-
tattoo, TLT, 70 (11), pp. 8-9.
structure of SIS was found to be ap- cur during stretching. Kumar says,
pealing because it combines the elas- Electrolytes can seep into the crack 2. Kumar, R., Shin, J., Yin, L., You,
J., Meng, Y. and Wang, J. (2017),
ticity of long polyisoprene chains (the leading to a drop-in voltage and as a
All-printed, stretchable Zn-Ag2O
homopolymer is natural rubber) with consequence reduce performance.
rechargeable battery via hyper-
the hardness of two short polystyrene Future work will involve boosting elastic binder for self-powering
terminal ends. the performance of the printed battery wearable electronics, Advanced
Kumar indicates that SIS is a highly and enabling it to recharge so that it Energy Materials, 7 (8), 1602096.
stable binder that will allow battery ink can be used over a longer operating
According to legend, U.S. manufacturers rejected Demings theories, prompting him to introduce them to the Japanese. 11
TECH BEAT
Photoelectrochemical generation of
hydrogen over 100% quantum efciency
A new photoelectrochemical cell generates better performance than
a photovoltaic cell using the same anode and cathode electrodes.
FINDING APPROACHES TO INCREASE THE for an organmetallic halide perovskite. of the number of electrons collected by
EFFICIENT CONVERSION OF SOLAR ENERGY This parameter represents the distance the photoelectrode cell per second to
into electricity and other useful prod- that an electron or a hole passes from the number of photons incident on the
ucts is a continuing focus of research. the point of generation until either the photoelectrode per second. Yan says,
A good deal of attention has been paid two species recombine or the electrons
to working with perovskitescrystal- are extracted into an electric eld. To
line materials containing organic and improve efciency, the diffusion length
inorganic components. must be extended. For this specic
This process is particularly
A previous TLT article discussed perovskite, the diffusion length is be-
research to determine the efciency tween 10-20 microns. effective at wavelengths of
of perovskites.1 A technique known as The use of solar energy to produce 450 nanometers and lower
scanning photocurrent microscopy was hydrogen through the splitting of water
used to measure the diffusion length can be done by a number of methods.
where a 10%-20% efciency
One attractive approach is through a boost from MEG is achieved.
photoelectrochemical process where
semiconductor electrodes convert so-
KE CONCEPTS
KEY CO C TS lar energy into the chemical energy of
hydrogen. When a photon interacts with the
A photoelectrochemical cell has
Yong Yan, assistant professor in the electrode, one electron and one hole
bee developed that exhibits a
been chemistry and environmental science pair are produced. The problem is that
quantum efciency exceedingg department at the New Jersey Institute high-energy photons having energy
100% inin the
thee ultraviolet-visible
ult a o et s b e of Technology in Newark, N.J., says, levels greater than the semiconductor
light range. There are three obstacles in the way band gap produce high-energy species
of efciently producing hydrogen using needing to relax. Unfortunately these
The cell used a technique known photoelectrochemistry. A material must species dissipate the extra energy as
as multiple exciton generation be used that absorbs solar energy in a heat leading to a loss of efciency.
that enables one high-energy
high-ene g similar fashion to solar panels. The cat- An approach that can be used to
alytic process for producing electrons capture this extra kinetic energy is
photon to generate multiple
and holes must be more effective to ef- known as multiple exciton generation
electrons.
ciently reduce water to hydrogen and (MEG). Yan says, In MEG, one high-
oxidize water to form oxygen. These energy photon can generate multiple
The researchers achieved this
two processes must be compatible with excitons and then electrons leading to
resultt by splitting hydrogen
result
each other. the potential for increasing the external
sulde into its elemental The challenge facing researchers is quantum efciency above 100%.
species, hydrogen and sulfur. to maximize the external quantum ef- Yan indicates that production of
ciency, which is dened as the ratio two electron-hole pairs can boost the

Figure 2 | A photoelectrode
(left) was used in the
photochemical cell on the
right to achieve a quantum
efciency greater than
100% in the generation of
hydrogen from solar energy.
(Figure courtesy of New Jersey
Institute of Technology.)
external quantum efciency to 200%. was as in a phosphate-buffered solution chemical cell generates better perfor-
Development of a photoelectrochemi- in a separate compartment. mance than a photovoltaic cell using
cal process that can boost the efciency The anode is exposed to white the same anode and cathode electrodes.
above 100% and also utilize photons in light that was passed through a mono- He says, In this system, it is very dif-
the more readily available, ultraviolet- chromator where electrons, holes and cult for the photovoltaic cell to produce
visible light range may lead to a more hydrogen cations are produced. Elec- an external quantum efciency above
efcient approach for producing hy- trons and hydrogen cations then move 100%. The problem is the hole recom-
drogen. Such a process has now been to the cathode where reduction leads bination and the interference light ab-
realized. to the formation of hydrogen gas. The sorption by the titanium dioxide in the
holes oxidize sulde to form free sulfur, ultraviolet-visible light range.
HYDROGEN SULFIDE SPLITTING which is dissolved in the sodium sul- For the future, Yan is working to de-
Yan and his colleagues developed a de solution. A salt bridge was present velop a photoelectrochemical cell that
photoelectrochemical cell that exhibits to connect the anode to the cathode will split water. He says, We need a
an external quantum efciency exceed- completing the electric circuit and en- better approach with more stable and
ing 100% in the ultraviolet-visible light abling sodium and hydrogen cations to applicable reactions that can take place
range. He says, Our system contains move from the anode to the cathode. at the anode and cathode.
an anode consisting of a lead sulde Yan says, In fact, we are splitting Additional information can be
quantum dot electrode deposited on hydrogen sulde into its elemental spe- found in a recent reference2 or by con-
top of a uorine-doped tin oxide/ti- cies, hydrogen and sulfur. tacting Yan at yong.yan@njit.edu.
tanium dioxide dielectric stack and a The cathode is kept in the dark to
cathode prepared from platinum. ensure that there is no interference
Yan continues, Quantum dots with the light-illuminated anode. The
consist of small quantities of semi- researchers measured the amount of
conductor particles a few nanometers hydrogen generated at the anode to the REFERENCES
in diameter that exhibit specic band known number of incident photons at 1. Canter, N. (2017), Unraveling
gaps. These materials are very good a specic wavelength. In adjusting the the effectiveness of perovskite
at absorbing energy and generating wavelength of light, they found that the solar cells, TLT, 73 (4), pp.
12-13.
electrons and holes. For our work, we external quantum efciency reached
chose lead sulde because this com- up to 120% with MEG producing two 2. Yan. Y., Crisp, R., Gu, J., Cherno-
pound has generated high MEG ef- low-energy electrons from a single mordik, B., Pach, G., Marshall, A.,
ciency in the past. high-energy photon. This process is Turner, J. and Beard, M. (2017),
Multiple exciton generation for
Figure 2 shows an image of the pho- particularly effective at wavelengths
photoelectrochemical hydrogen
toelectrode and the photoelectrochemi- of 450 nanometers and lower where a
evolution reactions with quantum
cal cell. The anode was placed in a one 10%-20% efciency boost from MEG
yields exceeding 100%, Nature
molar sodium sulde aqueous solution is achieved. Energy, 2, Article Number: 17052.
to facilitate ion ow and the cathode Yan indicates that this photoelectro-

TECH BEAT
Hexagonal close-packed
high-entropy alloy
The new material is radiation resistant, making nuclear reactors
a potential application.
THE DEVELOPMENT OF NEW ALLOYS con- ber was discussed.1 For the example arrangements. Face-centered cubic
tinues as researchers strive for materials of ve metals, each element would be materials exhibit high symmetry, which
that combine properties such as strength present in a high-entropy alloy at a con- means that planes of atoms can readily
and ductility that are not normally centration of 20%. A high-entropy alloy move relatively to one another. This
found together in most conventional al- based on mixing equal percentages of leads this type of alloy to be highly
loys. Most alloys usually consist of one aluminum, lithium, magnesium, scan- ductile in nature.
metal in a high percentage, which limits dium and titanium was discussed. The Few high-entropy alloys to date
the available alloy compositions. researchers who prepared this high- have been present in hexagonal close-
In a previous TLT article, a new class entropy alloy found that it displayed a packed structures and those that are
of high-entropy alloys that contains ve higher strength-to-weight ratio than any typically contain uncommon and ex-
or more metals in roughly equal num- other existing metal. pensive elements. Tracy says, The ap-
Dr. Cameron Tracy, post-doctoral re- peal of hexagonal close-packed alloys is
searcher in the department of geological that they are lower symmetry systems
sciences at Stanford University in Stan- and tend to be very hard and brittle.
KE CONCEPTS
KEY CO C TS ford, Calif., says, High-entropy alloys Ideally the way to develop a versa-
have enormous potential because there tile high-entropy alloy is to combine
A new high-entropyy alloyy has are many ways to combine metals in high strength with good ductility. In
been developed
de ped by converting equal concentrations. They can exhibit effect, can a material that is present
a material with a face-centered properties not found in conventional al- in both the face-centered cubic and
loys. High-entropy alloys that have been hexagonal close-packed orientations
cubic atomic arrangement to a
prepared display greater fracture tough- be prepared? Such a material has now
hexagonal close-packed
ness (or strength per unit mass) than been developed.
structure under high pressure. nearly all conventional alloys.
A second advantage for high-entro- HIGH PRESSURE
After
tter the pressure is relieved,
py alloys is the wide variety of metals Tracy and his fellow researchers decid-
the resulting alloy contains potentially will enable researchers to ed to take a well-known high-entropy
both face-centered and develop materials with many different alloy that was prepared from an equi-
h gonal close-packed
hexagonal close-pp ked combinations of properties. Tracy says, molar mixture of chromium, manga-
st uctu es leading
structures le g to the With the development of high-entropy nese, iron, cobalt and nickel and com-
potential to design
design
g materials
matte als alloys, researchers are not constrained pressed this material under increasing
by having to work with specic ele- pressure to produce a slow transfor-
with specic hardness
ha d s and
ments on the periodic table. mation from a face-centered cubic to
d tility properties.
ductility prop t es. The initial types of high-entropy al- a hexagonal close-packed structure.
loys produced have originated from a He says, We selected this particular
The transition
tr tion between
variety of metals but have been limited high-entropy alloy because it has been
stt uctu
structures
t es is probably
prob blly high by their lattice structure. Tracy says, widely studied over the past decade
because it is hard for atoms to Most of the high-entropy alloys de- and exhibits such positive characteris-
move around and
a d diffuse. veloped either consist of face-centered tics as good corrosion resistance, oxida-
cubic or body-centered cubic atomic tion resistance and strength.
14 Deming acquired a bachelors degree in electrical engineering at the University of Wyoming. He worked his way through college as a janitor.
a few years to see if the high-entropy
alloy reverts back to a face-centered
cubic structure.
Tracy believes that the move to the
hexagonal close-packed geometry leads
to a distorted structure where it is hard
for atoms to move around and diffuse.
The barrier for moving to a face-cen-
tered cubic could be energetically high.
The slow transition between phases
may enable the ratio of the face-cen-
tered cubic to hexagonal close-packed
to be adjusted to vary the hardness and
ductility to meet specic applications.
This may lead to the commercialization
of such alloys (see Figure 3). One ap-
plication is for use in nuclear reactors
because high-entropy alloys are very
resistant to radiation damage.
Figure 3 | High-entropy alloys produced by manipulating the arrangement of the atoms Future work will be done to see
could lead to unique materials that could be used commercially in applications where how subjecting the face-centered cu-
ferrous alloys are commonly used. (Figure courtesy of Stanford University.)
bic high-entropy alloy to elevated tem-
peratures (ranging from 5-1,000 C)
while under pressure affects the phase
The alloy is prepared by arc-melt- important in enabling this phase trans- transformation. Tracy says, Elevated
ing the metals under an argon atmo- formation to occur. Tracy says, Com- temperatures have been found to also
sphere followed by drop-casting to putational analysis shows that the dis- decrease magnetism.
produce an ingot. High-pressure ex- appearance of magnetism can promote Other work will include evaluating
periments were performed by taking a change from a face-centered cubic to different high-entropy alloys under
powder from the ingot and placing a hexagonal close-packed structure un- high pressure and evaluating the me-
it in a symmetric, diamond anvil cell der ambient pressure. The application chanical properties of these alloys. Ad-
in which the material is squeezed be- of pressure to a material typically re- ditional information can be found in a
tween two ultra-hard diamonds. duces its magnetism. As the magnetism recent article2 or by contacting Tracy at
X-ray diffraction showed that a of this high-entropy alloy breaks down cltracy@stanford.edu.
transformation to a hexagonal close- at high pressure, the order of the alloy
packed structure starts when a pressure also breaks down as planes of atoms
of 14 gigapascals is applied to the high- slowly shift into a hexagonal close- REFERENCES
entropy alloy. The researchers increased packed conguration. 1. Canter, N. (2015), High-entropy
the pressure to a maximum of 54 Once the pressure is relieved and alloys, TLT, 71 (3), pp. 14-15.
gigapascals. As the pressure increased, the alloy reverts to ambient pressure, a 2. Tracy, C., Park. S., Rittman, D.,
the ratio of hexagonal close-packed to segment of the hexagonal close-packed Zinkle S., Bei, H., Lang, M.,
face-centered cubic material increased. structure moves back to a face-centered Ewing, R. and Mao, W. (2017),
When asked about the reasons for cubic, but the high-entropy alloy re- High pressure synthesis of a
using high pressure, Tracy commented tains a good deal of the hexagonal hexagonal close-packed phase of
that his background in studying geol- close-packed structure. Tracy says, the high-entropy alloy CrMnFe-
ogy under high pressures in the Earths This behavior is unusual because in CoNi, Nature Communications, 8,
Article Number: 15634.
core where metals are present led to the most other cases the metal alloy will
current work evaluating high-entropy completely revert back to its original
alloys. He says, We felt high-entropy state. We are not sure why this specic Neil Canter heads his own
alloys have unique thermodynamic and high-entropy alloy is different. One consulting company, Chemical
magnetic properties that can change theory is that the hexagonal close- Solutions, in Willow Grove, Pa.
under pressure. packed structure is in a metastable Ideas for Tech Beat can be
The breakdown in magnetism un- state. To see if this is the case, we are submitted to him at
der high pressure appears to be very leaving samples at ambient pressure for neilcanter@comcast.net.

MARKET TRENDS
Sharbel Luzuriaga
Lubricant growth in Latin

America and the Caribbean
Can Stock Photo / monstersparrow
KEY CONCEPTS New economic models are

Latin America and
a d thee Caribbean are driving demand with Brazil,
among the worlds fastest-growing
lubricant-consuming regions. Mexico, Argentina and Chile
The
hee market
rket is expected to maintain
maintain
ta leading the way.
a shift toward technological
development,, as more advanced
engine oil
o performance grades enter
ente ALTHOUGH LATIN AMERICA AND THE CARIBBEAN contribute about
slightly less than 10% of the global nished lubricant demand,
in thee ne
near future.
the region remains one of the worlds fastest-growing lubricant-
The region
regi n iss characterized by high consuming regions, exhibiting a compound annual growth rate
(CAGR) of about 2% over the next ve years.
price sensitiveness, counterfeit
However, this general picture is primarily shaped by two ma-
products, parallel
p ll l imports
imp ts and low
low
w jor regional dominant players, namely Brazil and Mexico (see
end-user awareness
awarenes
aw ess of the benets Figure 1). These two countries display more conservative growth,
of lubricants.
lubr
b icants
ts. hiding several smaller but dynamic markets such as Chile, the
Dominican Republic, Panama and Costa Rica, where lubricant

observed in major energy and commodity-exporting countries
in South America, and less pronounced in net oil importers
in Central America.
In an attempt to remain less vulnerable to external turbu-
lences, local governments across the region have (or are in the
process of) implemented policy reforms, albeit at a varying
degree of success, in each country. The goal is to transform
heavily export-reliant markets into more competitive econo-
mies with a robust middle class and strong domestic market.
Therefore, it is paramount for lubricant suppliers operating
in Latin America and the Caribbean to be agile, offering a
lubricant product portfolio matching the emerging consump-
tion patterns in a region transitioning from high raw material
price/low nancing cost economies to low raw material prices/
high nancing cost economies.
NEW GROWTH AREAS

Beyond the Golden Decade there is a new era of growth
emerging in the Latin American and Caribbean nished lu-
bricants market; savvy lubricant suppliers must be open to
addressing new market needs.
Kline estimates the Latin American and Caribbean nished
lubricants market at around 3.7 million metric tons in 2015,
with the largest countries, including Brazil, Mexico and Ar-
gentina, accounting for more than 60% of the nished lubri-
cant demand in the region. By market segment, the industrial
segment accounts for 37% of demand, while the commercial
and consumer automotive segments represent 33% and 30%
shares of the total demand, respectively (see Figure 2).
Figure 1 | Finished lubricant demand in Latin America and the

Caribbean by country for 2015.
demand is posting above-average industry growth, as reported

by Kline in its recently published study titled Opportunities in
Lubricants: Latin America and Caribbean Market Analysis. In
this report, 17 countries from the Latin American and Carib-
bean region are covered.
REGIONAL DISPARITIES
The region exhibits remarkable disparities in growth between
commodity-exporting South American countries, compared
to more highly U.S.-reliant economies in Mexico and Central
America.
Following a bonanza fueled by soaring commodity prices
and exports to cater to Chinas insatiable appetite for raw
materials, the regional economies started to feel the adverse
effects of external and internal turbulences, ending a period
of economic expansion in the period spanning 2003-2013,
also known as the Golden Decade for the region. Due to het-
Figure 2 | Finished lubricant demand growth by segment for
erogeneity in Latin America, the extent of the negative impact the 2015-2025 period.
varies across the region, with the most negative impact being

The regional finished lubricant eration. In general, there are two types monogrades representing 40% share
market can be characterized by qual- of maritime engine oils: 2T and 4T. The and high-viscosity multigrades ac-
ity shifts promoted by the renovation most common viscosity is monograde counting for the balance. Low aware-
of the local car parc (i.e., total number SAE 40, followed by SAE 50 and SAE ness of the benets of lubricants and
of cars in a country or region) and the 30. All maritime oil requirements can adequate maintenance practices is
modernization of the industrial sec- be met with these grades. Some of the a recurrent issue observed in Latin
tor reconguring to more added-value largest cruise and marine transport America. The persisting myth among
manufacturing activities. The industrial companies prefer to carry lubricant Latin American end-users that the
lubricant segment is dominated by ex- stock and keep maintenance on board. thicker, the better the lubricant has
tractive and related industries, such as This preference among large companies yet to be completely defeated.
quarrying, mining, gas and oil extrac- for in-house maintenance continues to The Latin American consumer lu-
tion and rening, but also activities re- curb demand for lubricants and ser- bricant segment is characterized by
lated to the processing of commodity vices at the shipyard. high demand for high-viscosity mo-
products for exports, including agricul- The commercial automotive seg- tor multigrades such as 15Ws but also
tural and food-processing products, as ment is the second most important 20Ws and 25Ws; together, these grades
well as textile and light manufactur- outlet for nished lubricants in Latin account for about 60% of the passen-
ing. The automotive and its associated ger car motor oil demand in the region.
component supply industries consti- Demand for monogrades remains sig-
tute another important market outlet nicant (about 20%) in a region where
for lubricant consumption, notably in imports of aged vehicles from the U.S.
Brazil, Mexico and
Brazil and Mexico. The textile indus- are still very popular, despite the vari-
try is a key GDP contributor in Cen- Argentina account for ous initiatives to regulate this activity.
tral America and Mexico, with a dense more than 60% of Brazil and Chile have the most modern
network of maquiladoras operating car population, with car parcs having
in counties like Honduras, Guatemala
the nished lubricant an average age of eight and nine years,
and El Salvador. Sugar cane cultivation, demand in the region. respectively. Contrary to this, Colombia
and its processing industries, including and Ecuador have some of the oldest
bioethanol and biomass for power gen- car parcs with an average age around
eration, is creating demand for indus- 12 years in both countries. It is worth
trial nished lubricants in Brazil and America. Mining, construction, cargo mentioning that the Caribbean region
Central America. eet and public transportation, as well exhibits a strong consumer automo-
Process oils, hydraulic uids and as tourism, are among the most im- tive lubricant segment driven by the
industrial engine oils accounts for portant market outlets for commercial proliferation of private passenger cars
about 70% of the total industrial n- lubricants in the region. Given the un- services offering alternatives to means
ished lubricant consumption in Latin derdeveloped railroad infrastructure in of public transportation. In the Do-
America and the Caribbean. Process the region, the vast majority of all cargo minican Republic, private cars offering
oils are in relatively high demand and moved in the region is done via cargo public transportation services, known
nd application mostly in the food trucks and vehicles on the countrys in the local jargon as conchos, are a
processing, chemical, pharmaceutical terrestrial highway system. popular form of transportation.
manufacturing, textile and rubber in- Latin America is one of the most Primarily low-quality performance
dustries. Hydraulic uids are mainly urbanized regions in the world, with lubricants are used. There is low pen-
used in mining, steel manufacturing more than half of the population liv- etration of synthetic products and high
and machinery. In terms of demand by ing in major urban agglomerations. growth potential in the premium lubri-
grade, the most demanded hydraulic Latin American commercial lubricant cant product segment. Semi-synthetic
uid grade in Latin America is AW 68. demand also is composed of pub- PCMOs have gained ground in some
By industry, the mining industry rep- lic transportation eets, such as city markets, such as Chile and Costa Rica,
resents the largest end-use application buses, as it is the preferred method of as a result of modernization of the car
for industrial lubricants in Chile, Peru transportation. parc based on imports of new cars re-
and Bolivia. Conventional multigrade HDMO, quiring higher quality engine oils.
Within industrial engine oils, ma- 15Ws, continue to be the dominant On the other hand, penetration of
rine oils are the largest subcategory in grade for heavy-duty engine oils in synthetic and semi-synthetic PCMO is
Latin America. In some countries like Latin America, accounting for more still low in some high-volume markets,
Panama and Ecuador, it is reported that than 50% of the total heavy-duty mo- such as Mexico and Colombia, primar-
some portion of the engine oils classi- tor oil demand in the region, with ily due to the limited knowledge of ve-
ed as marine are used in power gen- sizeable consumption of SAE 30/40/50 hicle owners regarding the benets of
18 Deming started his career teaching mathematics and then physics at the Colorado School of Mines while pursuing a masters degree
The regional goal is to transform heavily export-reliant markets into more competitive
economies with a robust middle class and strong domestic market.
synthetic lubricants. Global majors Shell and ExxonMo- LOOKING AHEAD

Lower viscosity grade PCMOs, SAE bil, the top two suppliers of nished The outlook for the Latin American n-
0W-XX and SAE 5W-XX, currently ac- lubricants in Latin America and the ished lubricant market remains bright
count for a small share of 7% of the to- Caribbean, service the region through despite various challenges.
tal PCMO demand. These are expected macro distributors and are increasingly As the region starts to pick up, it is
to expand in 2020 to a share of 14% facing erce competition from local/ entering a new post-recession cycle in
and in 2025 to a share of 25% of the regional players, such as Petrobras, 2017. The regional differences emerging
total demand. The large motorcycle Ipiranga (Brazil), Akron (Ex-MexLub), show that growth will not be uniform
population in Brazil and Colombia are Roshfrans (Mexico) and YPF (Argen- and will largely depend on internal po-
the largest markets for 2T/4T motor- tina), among others. Some of these litical stability, as well as the stance the
cycle oils. contenders aspire to achieve more gains new U.S. administration will take in re-
from global majors, which are operat- lation to its southern neighbors.
KEY PLAYERS ing indirectly through distributors. Lo- Uncertainty around Brazils econo-
Major lubricant multinationals remain cal suppliers have successfully applied my, the largest market in South Ameri-
the leading market players in Latin manufacturing-driven strategies, hav- ca, which is immersed in a deep reces-
America, although their position is ing made inroads in low-tier lubricant sion, combined with high volatility of
being challenged by local players suc- segments, with lock-in blend plant ca- crude oil prices, are some of the factors
cessfully operating in the mid-tier and pacities with private label, service ll deterring a more robust growth in the
low-tier segments. and factory ll contracts. region. Since China became a major
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at the University of Colorado. He went on to accept a scholarship and acquire a doctorate in mathematics and physics at Yale in 1928. 19
importer of South American commodi-
ties during the last decade, from crops
like soya to meat, metals and crude oil,
the slowdown of the Chinese economy
also has affected the regions growth.
With overall volumes continuing to
decline in Brazil during the 2016-2017
biennial, the main challenge in the lu-
bricants industry is keeping protabil- Figure 3 | Forecast lubricant demand in Latin America and the Caribbean for 2015-2025.
ity levels and avoiding value destruc-
tion in search of higher volume share.
However, Brazil is forecast to start
recovering by 2018 in the best-case sce-
nario. This will be driving demand for
PCMOs, which are estimated to grow at
a CAGR of 2.5% through 2025. Mexi-
co, Central America and the Caribbean
will post robust growth due to a closer
connection with the U.S., as well as
benets arising from the low crude oil
prices, given the fact that this regional
cluster is a net importer of crude oils,
except for Mexico.
Furthermore, the vehicle parc is
based on secondhand imports where
primarily low-quality performance lu-
bricants are used. There is minor pen-
etration of synthetic products, as well
as a signicant presence of counterfeit
products.
The market is expected to maintain
a shift toward technological develop-
ment, as more advanced engine oil
performance grades enter in the near
future. However, this development
Figure 4 | Key growth products in Latin America and the Caribbean for 2015-2025.
evolves faster in larger markets, such as
Brazil, Chile and Mexico. Convention-
al multigrade PCMOs, 15Ws, 20Ws,
25Ws and SAE 40/50 will progressive- 2020 and 4.3 million metric tons in quiring a different set of competences to
ly lose ground, favoring premium 5Ws 2025, with Brazil, Mexico, Argentina be successful in a region characterized
and 0Ws fuel economy grades. These and Chile leading the way (see Figure by high price sensitiveness, counter-
are expected to expand in 2020 to a 3). Future growth in the region will be feiting issues, parallel imports and low
share of 15% from 7% in 2015. driven by an increase in exports and end-user awareness of the benets of
Conventional multigrade HDMO, trade deals with North America and lubricants (see Figure 4).
15W-40/50, continues to be the domi- other regions, namely the EU, as well
nant grade for heavy-duty engine oils as countries from the Pacic Rim.
in Latin America. This viscosity grade Penetration of synthetic and semi- Sharbel Luzuriaga is a Project
Manager at Kline & Co. in the
will see a maximum volumetric growth synthetic PCMOs, and HDMO is grow-
Energy practice. You can reach
within the next ve years. Whereas in ing in Latin America and the Caribbean,
him at Sharbel.Luzuriaga@
the industrial segment, process oils along with the modernization of the car
klinegroup.com. Kline is an
(PO), hydraulic uids (HF) and indus- parc. The region poses a high growth international provider of
trial engine oils (IEO) lead the demand. potential for volumetric organic growth. world-class consulting services
Finished lubricant demand in Latin Savvy lubricant suppliers will have to be and high-quality market intelligence for industries
America and the Caribbean is forecast open to putting in place differentiated including lubricants and chemicals. Learn more at
to reach 3.9 million metric tons in lubricant marketing strategies, each re- www.klinegroup.com.
20 For the next 19 years he worked for various branches of the federal government, starting as a mathematical physicist for the Department of Agriculture.
NA-LUBE KR Series
Broadest Range of Alkylated Naphthalenes SPECIALTY CHEMICALS
NA-LUBE KR Series alkylated naphthalenes are high

performance blendstocks primarily used with other synthetic
base oils or Group II & III mineral oils to:
Enhance thermal & oxidative stability
Reduce varnish formation
Synergistically reduce volatility
Extend lifetime of premium lubricants
Choose Kings NA-LUBE KRs for:
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NA-LUBE KR Typical Properties
NA-LUBE NA-LUBE
A-LUB NA-LUBE
A-LUB
Property KR-008 KR-01
KR-015 KR-019
KR-01
Visc. @ 40C 36 cSt 114 cSt 177 cSt
Visc. @ 100C 5.6 cSt 13.5 cSt 18.7 cSt
Noack Volatility 12.0% 2.2% 1.4%
Pour Point -33C -39C -26C
www.kingindustries.com
Made in the U.S.A.
20 MINUTES WITH
Rachel Fowler / Managing Editor
Michael Stapels
MICHAEL STAPELS: This research chemist with
The Quick File
Kao Chemicals GmbH discusses
foam countermeasures and why
he recommends ethercarboxylic
acids for the formulation of
metalworking uids.
TLT: How did you become involved with the metalworking

industry?
Stapels: My path to working in metalworking was somewhat

indirect. My rst contact to industry directly after the univer-
Michael Stapels is a research chemist sity was in the global R&D center of Unilever in Port Sunlight,
for Kao Chemicals GmbH. He studied UK. Here I was responsible for testing and optimizing cosmetic
chemistry at the RWTH Aachen Univer- products. During this period I was introduced and captivated by
sity in Germany where he received his the art of formulation. The lessons learned in this early stage of
doctorate in polymer chemistry in No- my career are still the fundament even for my current position at
vember 2001. Kao Chemicals where my team develops innovative surfactants
After a research associate position and additives with special focus on the metalworking industry.
at the Unilever Research Laboratory
Port Sunlight in the UK and other indus- TLT: In Europe your company is known as The AKYPO Co.
trial R&D positions, he joined Kao Chemi- Please explain this.
cals in October 2005. In his position as
technical manager and group leader, he Stapels: First of all, this underlines that for our company and for
is focused in the development of addi- our customer, the AKYPO brand is a vital and essential part of
tives for the metalworking industry, our product portfolio. From a chemists point of view, AKYPO
which includes the global technical cus- is the brand name for so-called ethercarboxylic acids. Ether-
tomer support. carboxylic acids can be regarded as interrupted soaps with the
Stapels has published and presented addition of a number of ethylene oxide (and also now available
papers at numerous technical confer- in combination with propylene oxide) groups between the alkyl
ences including STLE Annual Meetings chain and the carboxylate group and can be represented by the
and the TAE International Colloquium Tri- following chemical structure:
bology. He is a member of STLE and is
volunteering in the Metalworking Fluid
Education & Training Subcommittee.
22 Deming also was a lecturer in the National Bureau of Standards, head of the Mathematics and Statistics Division of the Dept.
R is derived from fatty alcohols and TLT: What are typical misconcep- emulsier but as a co-emulsier with
is between C4H9 and C18H37. The de- tions you are confronted with when all its impacts on dosage. If you nd
gree of ethoxylation is represented by introducing ethercarboxylic acids to an optimal balance in your formula-
n and usually lies between 2 and 20. M metalworking uid formulators? tion you will be for sure able to reduce
may be hydrogen (free acid) or a cat- uid maintenance costs and efforts sig-
ion such as sodium or magnesium. In Stapels: There are three major miscon- nicantly, but most important the uid
metalworking application ethercarbox- ceptions: lifetime will be enhanced. These factors
ylic acids are typically neutralized with should denitely be considered in your
alkanolamines to give the correspond- 1. Ethercarboxylic acids are foaming price/performance analysis.
ing ether carboxylate. Ethercarboxylic too much.
acids are very useful co-emulsiers 2. Ethercarboxylic acids are too TLT: You also mentioned foam. What
mainly for the formulation of soluble expensive. kind of countermeasures/recommen-
oils and semi-synthetics. 3. There is no need for hard water con- dations do you provide to potential
trol because our uids are used in users?
TLT: Why do you recommend the soft water areas and/or only with wa-
use of ethercarboxylic acids for the ter from a water treatment system. Stapels: I would like to highlight two
formulation of metalworking uids? major points:
Let me start with the last point: You Large product range
Stapels: In water-miscible metalwork- should never underestimate the effect Formulation know-how.
ing fluids formulations, emulsifiers of evaporation losses and the quality
constitute one of the most essential of the topping up water. As a rule of As The AKYPO Co. we offer a
components. As an integral part of met- broad range of different ethercarboxylic
alworking uid concentrates, the emul- acids. They differ in C-chain length and
sier stabilizes the resulting emulsion degree of alkoxylation. For metalwork-
and furthermore should facilitate tramp I was introduced and ing applications there are two main
oil removal and ltration during their captivated by the art groups: short-chain ethercarboxylic ac-
whole lifetime. In addition, emulsiers idsbased mainly on Hexanol (C6) or
need to fulll a whole range of further
of formulation. Octanol (C8)and long-chain ether-
requirements such as: carboxylic acids traditionally based on
Oleylalcohol. If you combine these two
Low-foaming tendency thumb you might calculate the follow- groups of ethercarboxylic acids in such
Good heat stability ing: Assuming a 1,000 L bath with a a way that they are tting perfectly to
Good toxicological and dermato- moderate water quality of 250 ppm, the rest of your formulation, you will
logical prole. depending on the evaporation losses end up in a formulation that provides
topping up of about 50-200 liters per both extraordinary hard water control
Keeping in mind that the largest day is necessary. If the topping up wa- and very good foam control.
component of the bulk uid in a met- ter quality also has a 250 ppm load, As the foam control becomes more
alworking process is watertypically you end up after one or two months and more critical over the years, we de-
90% or moreit is obvious that the with bath water quality of about 1,000 veloped special grades of ethercarbox-
water quality has a major inuence on ppmwhich is a signicant load! ylic acids where we additionally insert
uid stability and longevity. On the one There also are some hidden sources a block of propylene oxide between the
side, water quality (hardness) differs for increasing water hardness such as hydrophobic tail and the hydrophilic
drastically from region to region, and magnesite-bonded grinding wheels. head group of the molecule. These
on the other side the electrolyte load On the other hand, when using a kinds of ethercarboxylic acids are a
of the uid will increase during pro- water treatment system, you might de- viable alternative to standard prod-
cessing. The decreasing water quality crease the load of Ca2+ and Mg2+ ions in ucts because they have signicantly
affects the cutting uids balance nega- your system on the cost of an increas- lower foaming potential in combina-
tively. Using ethercarboxylic acids in ing Na+ concentration, which also neg- tion with more efcient emulsica-
the emulsier package decreases the atively inuences the emulsion quality tion. The concept of propoxylation in
uids sensitivity toward water quality and stability. order to reduce foaming is not limited
signicantly and thus enables long- I will only briey comment on the to ethercarboxylic acids. Thus, it also
time use of a high-performance cut- price and cost situation. For judging nds widespread use in our industry
ting uid without regional restrictions the performance of ethercarboxylic (e.g., in alkoxylated alcohols (nonionic
or modications. acids, you should keep in mind that emulsier) and alkoxylated phosphate
the recommended use is not as a main esters (anionic emulsier)).
of Agriculture and chief mathematician and advisor in sampling and survey techniques for the Bureau of Census. 23
TLT: How signicant is the impact
of formulation on the uids perfor-
mance. Can you provide an example
of improved behavior just by an
optimized formulation?
Stapels: Lets choose a low-oil semi-syn-

thetic formulation based on sulfonates
as a starting point (formulation A, ba-
sis in Figure 1).This basis formulation
shows a very high foaming potential
(see Figures 2 and 3). Accordingly the
use of defoamers will be unavoidable
for the nal application. Typically the
rst tests of formulators with ethercar-
boxylic acids and/or nonionics is their
addition to existing formulations, so to
Figure 1 | Semi-synthetic metalworking uid formulations with different emulsier packages.
formulate on top (formulation B).
Doing so, the improvement in foam-
ing behavior is somewhat limited (see
Figures 2 and 3). Therefore, we usually
do not recommend to formulate ether-
carboxylic acids on top but to consid-
erif possiblethe whole emulsier
package. In the given example we op-
timized the amount of sulfonate, fatty
acid, ethercarboxylic acid as well as
the nonionic emulsier. The resulting
optimized formulation (formulation C)
shows an excellent foaming prole as
well as a signicantly increased hard
water tolerance due to the presence of
ethercarboxylic acid.
TLT: How does your lab support the

metalworking industry?
Stapels: As a strategic decision, our lab

in Germany has its main focus on the Figure 2 | Time dependent plot of foam height for 10% w/w dilutions of formulations
metalworking industry. The team is a containing different emulsier packages at a water quality of 250 ppm. Measurement
sound mixture of synthesis and formu- includes 10 s of foaming and 20 s of foam collapse, tested with a Krss DFA100 Dynamic
lation scientists working hand in hand Foam Analyzer.
in the lab.
Accordingly, one important pillar
for us is to provide mutual support by the best solution to our customers. know-how developed over decades. As
our experienced technical sales man- From my point of view, our success a chemist you have lots of possibilities
agers and scientists to our customers is invigorated by our close contact to to change a moleculejust to men-
and also to keep contact to the end- our customers and the vivid discussion tion raw material, synthesis strategies
users. Here we can take advantage from and joint developments over the last including change stoichiometry, pro-
our geographic position in the middle decade. In order to strengthen this even duction conditions, catalyst, etc. For
of Europe where a relevant number of more, we are extending our international example, additives coming along with
global key accounts are easily accessi- presence by joining important meetings, the same CAS number may exhibit
ble. It also is very important to under- conferences and education courses. drastically different behavior in the -
stand regional differences from a tech- The other important pillar for our nal application. The more you under-
nical point of view in order to provide support is the synthesis and product stand the impact of the chemistry on

METALWORKING
ADDITIVES
AKYPO
AKYPO ROX
AMIDET
Emulsion stability
Lime soap dispersion
Hard water stability
Foam control
Corrosion inhibition
Rinsing and cleaning
ESSENTIALS FOR
LONGER LIFETIME
METALWORKING FLUIDS
Enriching lives,
in harmony with nature.
THE TECHNOLOGY OF KAO SURFACTANTS IN METALWORKING FLUIDS
Distributed in North America by: KAO Chemicals GmbH

Sea-Land Chemical Co. Kupferstr. 1 - D-46446
821 Westpoint Pkwy. Emmerich am Rhein
Westlake - OH 44145 Phone: +49 2822 711 0
Phone: (440) 871-7887 Fax: +49 2822 711 201
marketing@sealandchem.com metalworking@kaochemicals.de
www.sealandchem.com www.kaochemicals-eu.com
ly accelerated, direct and efcient stability testing and ranking
of our formulations. By looking at the whole sample, we can
measure stability as well as understand the causes of instabili-
ty (e.g., occulation). Obviously accelerated emulsion testing,
determination of HLB values and increased understanding of
instability is a benet for a producer of emulsiers, but the
last pointranking our formulationsgives a particular link
to metalworking application.
Let me explain why. During this interview I talked quite
a lot about foam. Everybody in our industry knows that the
quality of an emulsion has a huge impact also on the foam-
Figure 3 | Foam height 15 s after shaking for 10% w/w dilutions
ing performance as a rule of thumb (with all its limitations):
of formulations containing different emulsier packages at a
The more instable the emulsion, the less foamy it is. When
water quality of 250 ppm.
comparing the foaming performance of different formulations,
it is very important to be aware even of minor changes in
the performance in metalworking, the more reliable you will the emulsion quality. And this is exactly the point where a
be for any customer since metalworking applications are very standard rapid measurement with the analytical centrifuge is
sensitive to performance uctuation. benetical (statistically very robust!) by providing a so-called
instability indexwhich is an objective gure allowing to
TLT: Describe an important instrument the lab has recently predict the long-term emulsion stability.
acquired for supporting research in additives. Accordingly we are now able to collect routinely the in-
stability index of our emulsion and correlate other test results
Stapels: My current favorite is an analytical centrifuge that (i.e., foaming performance) with this information.
measures instantaneously the extinction of transmitted light
across the full length of a sample. This sounds somewhat so- You can reach Michael Stapels at
phisticated, but with this tool we are able to perform physical- michael.stapels@kaochemicals.de.
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26 Deming developed his approach to quality management by combining earlier statistical theories of mass production with his own thinking.
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LUBRICATION FUNDAMENTALS
Dr. Robert M. Gresham / Contributing Editor
Words
mean
things
Can Stock Photo / prescott09
Especially when it comes to

3D printing, which could be
KEY CONCEPTS on the verge of ushering in
Additive manufacturing is
a process that builds 3D
a third Industrial Revolution.
objects by adding layer
upon layer of material.
The applications for additive WE HAVE ALL ENDURED SITUATIONS where we thought we had said
manufacturing are virtuallyy things quite clearly and later found that we were completely
misunderstood. This can be quite unsettling, especially if the
limitless.
audience for what we said was quite large. This happened to us
GE Aircraft Engine Grou
Group is in working on the second iteration of the STLE Emerging Trends
Report survey. With careful re-analysis of the results, we should
now printing blades for
for the
be able to correct the error, so not to worry. However, this is an
low-pressure turbine of the example of words mean things, but not necessarily the same
GE9X jet engine, the largest thing to different people.
jet engine ever built.
28 Demings philosophy stressed cooperation among employees rather than competition. It called for
In our survey, we asked about the
importance of additive manufactur-
ing. As you might guess, most folks
thought it was pretty important. One
group thought it would be more and
more important to manufacture both
old and newly developed additives
for lubricants with better quality and
lower cost. Yet another group thought
that additive manufacturing, based on
3D printing, would be the wave of the
future.
Yup, words mean things!
Lets take a closer look. Additive
manufacture (AM) in this second con-
text is to differentiate between addi-
tive and subtractive manufacturing. In
subtractive manufacturing material is
removed or subtracted from the work Figure 1 | TiAl powder and nished components inside an Arcam 3D printer in Cameri,
piece. Examples are most machining Italy. (Figure courtesy of Avio Aero.)
operations: sawing, milling, drilling,
grinding, etc. This, of course, results
in a lot of wasted material, which may totyping focused on preproduction of Milan and Turin, in tiny Cameri, It-
or may not be recyclable. visualization models. More recently, aly. In 2013 GE Aviation acquired Avio
AM is an appropriate name to de- AM is being used to fabricate end-use Aero, one of the most advanced Euro-
scribe the technologies that build 3D products in aircraft, dental restora- pean additive manufacturing compa-
objects by adding layer upon layer tions, medical implants, automobiles nies. They also have bought operations
of material, whether the material is and even fashion products. It also is a in Sweden, Germany and now several
plastic, metal, concrete or, one day, visualization tool in the design process. locations in the U.S.
perhaps even human tissue. Futurolo- Thus, it is a means to create highly The typical palette of materials used
gist Jeremy Rifkin has claimed that 3D customized products for consumers for 3D printing can range in complex-
printing signals the beginning of a third and professionals alike. It can be used ity from simple plastics to advanced
industrial revolution succeeding the as- for industrial tooling, producing small superalloys. For example, the GE Au-
sembly production line that dominated lots of production parts and, more and burn, Ala., factorys direct metal laser
manufacturing starting in the late 19th more, large lots of production parts. melting (DMLM) machines create jet
Century and was popularized by Henry One most notable example is the engine fuel nozzles by fusing layers of
Ford for building cars. use of AM by the General Electric ne metal powder with a powerful la-
Common to AM technologies is the (GE) Aircraft Engine Group. GEs cen- ser. Each layer is between 20 and 80
use of a computer 3D modeling soft- terpiece plant is located on the at and microns thick, thinner than a human
ware (computer-aided design or CAD), fertile plains that stretch seemingly for- hair, and an inch of printed material
3D machine equipment and layering ever between Italys industrial dynamos can contain up to 1,250 layers. Planes
material. Once a CAD sketch is pro- powered by jet engines that use these
duced, the AM equipment reads in data fuel nozzles already are ferrying pas-
from the CAD le and lays downs or sengers across Europe and Asia.
adds successive layers of liquid, pow- Additive manufacturing The Cameri plant uses 3D printing
der, sheet material or other materials, machines that use an electron beam to
in a layer-upon-layer fashion to fabri-
is being used to fabricate fuse together layers of a wonder mate-
cate a 3D object. The term AM encom- end-use products in rial called titanium aluminide (TiAl),
passes many technologies including aircraft, dental which is 50% lighter than the previ-
subsets like 3D printing, rapid proto- ously used nickel-based alloys (see
typing (RP), direct digital manufactur- restorations, medical Figure 1). The electron gun accelerates
ing (DDM), layered manufacturing and implants, automobiles the beam until its several times more
additive fabrication. powerful than lasers currently used
and more.
AM application is limitless. Early for printing metal parts. GE can build
use of AM in the form of rapid pro- blades from layers that are more than
continuous improvement and the use of statistical measurements to track the quality of products. 29
of the GE9X jet engine, the largest jet engine ever built (see
Figure 2). This engine is a mix of both evolutionary and revo-
lutionary technologies. The GE9X is the most fuel-efcient,
on a per-pounds-of-thrust basis, that GE has ever built. It
delivers 10% improved fuel burn versus the current GE90-
115B powered Boeing 777-300R and a 5% improved specic
fuel consumption versus any twin-aisle engine available plus
achieve an approximate 10:1 bypass ratio, a 60:1 pressure
ration and margin to Stage 5 noise limits.
This is merely one example of what can be done with this
exciting new technology that clearly will be an emerging trend
in many, many industries for years to come. There will still
be tribology issues with the mechanics of the 3D printer and
associated equipment but of a different nature than encoun-
tered in subtractive manufacture. It also is an example that
Figure 2 | Blades are being printed by GE for the low-pressure words mean things, but not necessarily the same thing to
turbine of the GE9X jet engine. different people, especially those who manufacture additives
for lubricants.
four times thicker than those used by laser-powered 3D print-

ers. They say the method is so fast that its competitive with
casting, the standard way to make parts from TiAl. There is
still nal surface nishing, but the material lost is negligible
versus standard subtractive manufacture for the whole part. Bob Gresham is STLEs director of professional development.
GE is now printing blades for the low-pressure turbine You can reach him at rgresham@stle.org.
Performance and service that are
LEADING EDGE
People and specialty products
you can count on.
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30 Deming created his System of Profound Knowledge, a comprehensive theory for management organized around 14 Points for Management.
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WEBINARS
Debbie Sniderman / Contributing Editor
Selecting the right

PLANE BEARINGS
They do jobs other bearings cant, but understanding their
heat, friction and material properties is critical.
KEY CONCEPTS
Dissipating the heat

plane bearingss generate
is critical to avoiding
plane bearing failure.
Can Stock Photo / MeisterPhotos
Graphene, Teon and

other additives
additi es affect
slipperiness and wear in
polymer
l plan bearings.
plane
Plane
Pla e bearings offer
Pl offe
advantages for many
applications wh
wheree
rolling bearings cant be
used.

MEET THE PRESENTER
This article is based on a Webinar originally presented by STLE Education on Aug. 24, 2016. Plane
Bearings is available at www.stle.org: $39 to STLE members, $59 for all others.
Robert Adams is U.S. director of engineering at Serapid, a manufacturer of lifting and moving sys-
tems using rigid chain technology. Adams also is CTO of Tribis Engineering, a company that performs
tribological testing and consulting. He is an adjunct professor at Oakland University, teaching under-
graduate and graduate tribology, and says that plane bearings are his passion. You can reach Adams
at radams@tribis.net.
Robert Adams
PLANE BEARINGS ARE THE SIMPLEST an apparent contact area is used, and the bonds break and dont have time
TYPE OF ALL BEARINGS but also some the frictional force is independent of to fully form again, the friction force
of the least understood. For the this apparent area. is kinetic. If the kinetic friction were
purpose of this article, there are two The third law: The coefcient of higher, it would stop the motion.
types of bearings: plane and rolling sliding friction (also known as the The coefcient of friction is not
element bearings. kinetic friction) is independent of a material property but, rather, a
Plane bearings are surface contact the sliding velocity. complex system response. It is re-
bearings that slide. The name comes The fourth law is that kinetic lated to surface roughness; environ-
from planar contact, but the con- friction is always less than static ment such as temperature, vacuum
tact is not always planar. The most friction. When two surfaces arent or atmosphere; working conditions
primitive bearings are two at sur- moving, static friction is large. As- such as lubricant, load and speed;
faces sliding on each other, but plane perities micro-weld to each other and bulk properties. Plane bearings
bearings can be cylindrical, spherical and bond. When motion starts and are part of systems with complex
or have interesting proles. surfaces slide relative to each other, relationships, and sometimes sur-
A lot goes into selecting plane
bearings. Whether they are low or
high cost, making poor material se-
lections for a given application can
have catastrophic costs.
BASIC LAWS OF FRICTION

To understand how plane bearings
work, its important to understand
basic laws of friction. The rst law
states that frictional force depends
on the coefcient of friction and
the load carried by the bearing:
F = L (see Figure 1).
The second law: Friction is in-
dependent of apparent area of con-
tact. When two surfaces touch each
other, they arent perfectly confor-
mal and dont touch each other ev-
erywhere. The area where they do
contact is where friction occurs, but
it cant easily be measured. Instead, Figure 1 | Coefcient of friction surface chart for the Igus J plane bearing.
Point 1: Create a constant purpose toward improvement. Plan for quality in the rst place instead of nding detects in the product afterward. 3 3
prising behaviors can be seen in fric- Adams, U.S. director of engineering at mainly in academia. It is the volume
tion tests. Friction maps showing the Serapid, says, The force due to friction of material that is removed per unit
relationships between coefcient of cant simply be calculated by looking of time, typically per hour since wear
friction, contact pressure and velocity up values in a table. But formulas can rates are low.
of various plane bearings show widely help understand the concept of what is The specic wear rate is unitless
differently behaviors. happening in plane bearings. and species how much material is
Bowden and Tabor theorized that fric- worn in nanometers per meter of slid-
SLIDING FRICTION MECHANISMS tion was proportional to shear strength of ing distance, in nm/m (see Figure 2). It
The rst basic mechanism of friction in the material and inversely proportional to is related to the volumetric wear rate by
plane bearings is asperity interlocking. surface hardness: + | oa /H. Maintaining the contact pressure. Divide volumetric
As two surfaces slide, asperities may low shear strength at the points of con- wear rate by contact pressure to get the
interlock and shear or tear each other tact can keep friction down. Increasing specic wear rate.
loose, creating wear debris. In general, surface hardness also decreases friction. The traditional wear model is the
reducing the surface roughness reduces High degrees of smoothness decrease PV model, or wear velocity. Its com-
friction. asperity interlocking, but there might monly seen in commercial catalogs and
Adhesion is the next mechanism. be more asperities in contact. Depend- literature, but its units are complex,
The Bowden and Tabor adhesive fric- ing on the material, having a surface and I dont advise using it, Adams
tion theory says when surfaces con- that is too smooth could increase its says. Wear rates are typically in terms
tact each other, they bond. On a micro friction. Polyamides exhibit this behav- of 10E-9 inches of wear per hour. It is
scale, asperities contact each other and ior and will have high friction if the calculated from contact sliding pres-
cause deformation and adhesive bonds. surface is too smooth. The rough sur- sure, velocity and a material constant
During sliding, when relative motion faces in composite materials can shear according to:
occurs, the bonds rupture at the inter- and ll in low spots, and soon create a
face or in the mating bodies. The shear- smooth sliding surface. w=PVk
ing and breaking of these bonds result
in adhesive friction. LIFE AND FAILURE w = Wear velocity
Frictional force caused by adhesion To understand how long a bearing P = Contact pressure
is proportional to the real area of con- will last, its important to look at wear. V = Sliding velocity
tact and the shear strength of those ad- There are three wear models, each ac- k = Material constant
hesive bonds. There is no way to know cepted and used by different people.
the real area where micro-welding oc- The volumetric wear rate, also The PV power model is used in
curs, only the apparent area. Robert known as the Archard wear rate, is used industry and has made its way into
standards, specs and requirements.
But for plane bearings, bearing life is
really dened by the amount of allow-
able wearhow much material can be
lost, Adams says. Depending on the
application, allowable wear may be
anywhere from a few hundred microns
to a few millimeters. In rolling element
bearings, bearing life is generally based
on fatigue. There is no fatigue in plane
bearings.
The units of PV can be written as
Watts/mm2. This implies that PV is a
power model and is interpreted as the
amount of energy that can go into the
bearing at its surface before it fails.
Graphs in bearing material catalogs
show wear tests with time at various
PV values. At higher PV, the wear rate
is higher.
PV graphs start with design crite-
ria and designate safe areas that take
Figure 2 | Wear rate surface chart for the Igus J plane bearing. into account max pressure, max sliding
34 Point 2: Adopt the new philosophy. Embrace quality throughout the organization.
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velocity and a safe PV value (often be-
low 10,000 psi ft/min). But following
these rules you will still fail, Adams
says. Using the PV factor assumes it
is proportional to wear. In reality, the
thermal limit is what causes bearing
failure (see Figure 3). Always take PV
limits on plane bearings with a grain of
salt. People demand them and manu-
facturers provide them because theyre
requested in specications, but manu-
facturers wont stand by them.
Plane bearings generate heat at their Figure 3 | Plane bearing thermal failure. Figure 4 | Fan bushing thermal failure.
surfaces. If it cant be dissipated it over-
heats, causing bearing failure (see Fig-
ure 4). A more useful tool is to look thumb, a conservative estimate of heat dicator of material capability. The PV
at the amount of heat generated at the generation may be made by assuming limit found is highly dependent on the
surface of a plane bearing given by: the coefcient of friction to be 0.25. heat dissipation capability of the test
Performing a thermal analysis of the system. Depending on the test system,
H=PV heat at the wear surface will indicate PV limits may vary by two orders of
if the temperature will catastrophically magnitude. For published catalog, PV
where is the coefcient of friction. climb and melt the bearing or if it will limit values are not a property of the
Finite element analysis (FEA) soft- dissipate and the bearing can continue material but a listing of material be-
ware is helpful to calculate heat ows to run. havior on that particular test system,
in complex parts. As quick a rule of PV limit testing is not a good in- Adams says.
36 Point 3: Stop depending on inspections. They are costly, unreliable and dont improve quality.
Polymer Bearing Materials
Phenolic (composites) Polyimides Polyethylene POM (acetal copolymer) Acetate (cellulosics)
CIP Kapton HDPE, UHMW Delrin Tenite
Orkot Meldin Poly-Steel Celcon Butyrate
Micarta Vespel Tivar Hostaform PC (polycarbonate)
Mylar Turcite Lucite
Polyamides Urethanes Cyrolon
Nylon PTFE, FEP, PFA PCTFE PEEK (polykeytones)
Nycast PPS, PS (sulde (uoropolymers) Torlon
Zytel polymers) Teon Ultraon
Nomex Ultraon Rulon Arlon
Kevlar Ryton Fluoroloy
Figure 5 | Polymer materials used.
PLANE BEARING MATERIALS

Many materials are used for plane
bearings. Figure 5 shows a sample of
the types of polymer materials used.
Often manufacturers start with an in-
expensive material and create good in-
expensive bearings by adding friction
modiers such as Teon or graphite
to reduce friction and glass to in-
crease stiffness. The same method
can be used with expensive materials
to make phenomenal bearings. Secret
sauces are blends of the additives.
When theyre added to simple poly-
mer materials, they can create some-
thing that is very slippery.
The magic lubricant PTFE, com-
monly known under the trade name
Teon, is popular for use in bearing
materials as well as hoses, fuel lines
and anything else that has to last a long
time and not degrade (see Figure 6).
It is chemically inert, doesnt bond or
stick to other materials well and main-
tains low levels of friction. It is a very
smooth, long molecule that looks and
behaves like oiled spaghetti, mean-
ing that its slippery and hydrophobic.
Water, alcohols and other highly polar
oxygen and hydroxyl containing com-
pounds wont adhere to it, adsorb on it
or wet it. This is because of the high
electronegativity of the uorine; the
molecules outer electron orbitals are
Figure 6 | Teon materials built up on the surface of a steel test disk and torn from the bear- completely lled, making the molecule
ing make micro-thin coatings of the bearing material on the mating surface that cant always highly stable.
be seen. They ll in the valleys in the surface. In this region there is low shear strength and Graphite and other materials with
high hardness, giving low friction. (Figure courtesy of Tribis Engineering.) similar hexagonal structures, such as

molybdenum sulde MoS2 and tung- plane bearings is typically 2-20 nm/m. at wiping it out of the way. Small con-
sten sulde WS2, are often added to When wear amounts are 20-100 nm/m, taminant particles embed in the bearing
bulk materials to reach a desired lubric- the material is considered to be mod- material and are being removed from
ity. Graphite has strong in-plane bonds erate and not really made for plane the wear surface. When contaminants
within its layers of hexagonal benzene bearings, such as unmodied low-cost are harder and attached to the wear sur-
rings and weak ones between layers, al- ultra-high molecular weight (UHMW) face, like the little pieces of weld spat-
lowing planes to shear easily and create polyethylene. Materials that wear more ter, they cause grooves in the bearing
low friction (see Figure 7). Metals such than 100 nm/m exhibit catastrophic but not cause failure.
as nickel and silver are popular additives wear and may begin to roll and look Plane bearings can be used in appli-
that strain graphites bonds and lower its like uff spitting out from behind a cations that work at very high speeds.
shear strength (see Figure 8). wear surface. Ive never seen a real velocity limit on
Lubrication is frequently used on plane bearings. As long as the heat can
plane bearings. It lowers its friction be dissipated, they can be used, Adams
and adds an additional layer of protec- says. They also offer many other advan-
tion but slows down the formation of tages, are available in small sizes and a
a benecial transfer lm at the surface. variety of materials, provide excellent
The coefcient of friction in plane vibration dampening and are impact
bearings is estimated to range from resistant. They can run with soft metal
0.05 ). ) 0.10 when lubricated and surfaces, in vacuums, corrosive or high-
slightly higher at 0.10 ) ) 0.30 when temperature environments and can be
dry. By rule of thumb, coefcient of tailored for their operating environment.
friction is conservatively estimated to They also can be used in environmen-
Figure 7 | Singular molecular layer of graph- be 0.25 for most plane bearings. If an tally sensitive applications, on soft metal
ite. (Figure courtesy of Tribis Engineering.) actual value is needed, test the specic surfaces and in food handling.
material and surface condition to get There are disadvantages to using
a better estimate for specic operating plane bearings, and the majority of
conditions. them involve heat. They generate heat
and have poor heat dissipation. They
PLANE BEARING APPLICATIONS experience higher friction than ball
Plane bearings are used in applica- bearings. And a plane bearing can be
tions that cause rolling bearings to fail. thermally and electrically insulating,
Theyre used anywhere with extreme which could be an advantage or disad-
loads, like in the giant Hale telescope. vantage, depending on its use.
They tolerate far higher loads than ball Heat management is key to using
bearings of comparable size. plane bearings, and its typically over-
Applications with oscillating loads looked. The goal is to dissipate as much
Figure 8 | Intercalated graphite has metal
cry out for plane bearings; if a ball bear- heat as possible. Heat dissipation is
atoms between its graphite planes that
ing cant roll over several times, it will most commonly addressed in applica-
stress bonds and reduce shear strength.
(Figure courtesy of Materialscientist at English fail. Oscillating back and forth, a ball tions with intermittent use that provide
Wikipedia [CC BY-SA 3.0] (http://creative- bearing cant distribute its lubrication rest time to equalize temperatures. If
commons.org/licenses/by-sa/3.0) or GFDL and will fatigue quickly. duty cycles are kept low and there are
(www.gnu.org/copyleft/fdl.html)], via Wiki- Applications with large static loads only a few, heat management can be
media Commons.) or impact loads would fracture a ball ignored because every time it operates
bearing, so plane bearings are used. it cools off before the next cycle.
Any applications involving low speeds,
intermittent motion or vibration are Debbie Sniderman is an engineer and CEO of VI
PLANE BEARING PERFORMANCE good for plane bearings. Anything in- Ventures, LLC, an engineering consulting com-
One way to measure bearing perfor- volving electrical potential needs plane pany. You can reach her at info@vivllc.com.
mance is to look at its wear. The di- bearings because electricity passing
mensionless specic wear rate indi- through a ball erodes its surface. In
cates the amount of material removed this case, use plane bearings without FOR MORE INFORMATION
in nm, per meter of sliding distance. metallic llers such as bronze or other
Serapid: www.serapid.com
High quality bearing materials on pla- electrically conductive materials.
nar surfaces typically exhibit excellent They are simple bearings that can Tribis Engineering: www.tribis.net/
wear of <2 nm/m. Wear in lower cost tolerate contamination and are good
38 Point 4: Use a single supplier for any one item. The less variation in the input, the less variation in the output.
FEATURE ARTICLE
Dr. Nancy McGuire / Contributing Editor
Moneyball for
uid development
Statistical design of experiments couples
a numbers-based approach with practical
experience to extract the most information
from the fewest experiments.
Can Stock Photo Inc. / kadmy

Statistical design of experiments (DOE) got its start in the 1920s when British
statisticians Ronald Fisher and Frank Yates devised the method as a means of
making breakthrough discoveries. Their brainchild involved lengthy and detailed
mathematical calculations, and applying it required a deep knowledge of statistics.
DOE use increased during the industri-

al boom following World War II. Dur- &t

ing the 1950s, U.S. statistician and en-
gineer W. Edwards Deming introduced /&
the idea of statistical quality control to
industries in Japan, U.S. manufacturers D
DW

having already rejected his theories.
Statistical methods for quality con- > >
trol and product development gained
traction in the U.S. during the 1990s,
with such initiatives as Total Quality ^
Management and Six Sigma, aided by
the emergence of desktop computers
&
that took on the burden of performing
the calculations and assisted in inter-
preting the results.1 W
The steady evolution of DOE soft-
ware has made this approach more
accessible to non-experts with a ba-
sic knowledge of statistical principles. Figure 1 | The relationship between additive packages and uid properties and performance is
Today DOE is used for such things as complicated. For example, additives that improve lubricity (solid line) also might affect emulsion
reducing the amount of scrap in a ski stability and foaming (dashed lines). (Figure courtesy of Philip Zhao, Houghton International, Inc.)
manufacturers operations, coming up
with a new paint that wont peel off of an
aluminum tractor body and nding new
formulations for metalworking uids. MORE INFORMATION developing lubricants and metalwork-
FROM FEWER EXPERIMENTS ing uids. STLE-member Yixing (Phil-
Statistical DOE uses numerical screen- ip) Zhao, senior research scientist and
ing and modeling methods to extract innovation team leader at Houghton
the maximum amount of information International, Inc., in Valley Forge, Pa.,
from the minimum number of experi- notes that metalworking uid devel-
ments. Fluid formulations developers opers often use a one-factor-at-a-time
use this systematic method to narrow approach, sometimes called an Ediso-
their list of additive candidates, identify nian approach. This method is good for
the formulation components that have initial screening efforts but often falls
the strongest effects on performance, short during optimization, he says. Its
examine interactions among multiple not uncommon for a metalworking
components and devise an optimum uid to have 15-20 components, and
formulation window (including cost, many of them interact with each other
performance and stability factors) that (see Figure 1).
they can then validate in the lab. This industry really needs DOE,
This method is widely used in many Zhao says. Were a small industry with
industries (pharmaceuticals, for exam- limited resources and a reliance on old
ple), but its just beginning to emerge in knowledge. Theres a reluctance to use
Point 5: Improve constantly and forever. Emphasize training and education so everyone can do their jobs better. 41
DOE, but this could revitalize the area
and bring more efciency. He notes
a certain reluctance to part with the
old methods, but DOE lets developers
serve customers better and discover
new chemistries as well as conrming
whether new additives will work.
DOE can help you identify corre-
lations among multiple additives and
between additives and properties, he
says. Testing one variable at a time re-
quires a lot of experiments and doesnt
show you synergies and correlations.
In addition, he notes that DOE reveals
new correlations, cuts down on the
number of samples you need to test and Figure 2 | DOE software provides several capabilities that bridge the gap between individual
keeps you from running in circles when components and the desired properties of the resulting uid formulation. Laboratory experi-
interactions among additives introduce ments serve as input. The software identies correlations, which are statistically analyzed
complexity (see Figure 2). and used to nd optimal compositions. (Figure courtesy of Hoon Kim, Chemetall.)
Using DOE doesnt diminish the
value of personal experience, Zhao
emphasizes. You still need to do the gives you 28 or 256 experiments, if you into play. Are you going for low cost?
initial testing. We dont run hundreds are doing a complete DOE including Best performance? The DOE software
of samples like the pharma industry high and low values. To minimize the will calculate the formulation range
does, he says. You have to pick your number of experiments, he says, You that maximizes what youre going for.
samples for the initial work and under- want to test the variables with the most Formulations in this range are then
stand what the results actually mean impact. He adds that screening experi- tested in the lab to validate the results.
and how signicant the effects are. ments narrows the number of variables Zhao chooses the three or four most
so that you can test the broadest range effective additives for the next phase of
STEP BY STEP possible for each variable without caus- the statistical analysis. He uses a facto-
Dan Trauth, process research leader ing the experiments to fail. rial DOE method (testing all combina-
at ANGUS Chemical Co. in Buffalo Thus, the typical DOE process for tions) to identify correlations among
Grove, Ill., was already an experienced uid formulations involves two or three the additives and optimize the formula-
DOE user when he rst became in- phases. In the rst phase, developers tion. He notes that in some industries,
volved in uid formulations. He had run screening tests in the lab, replacing like pharmaceuticals, where the num-
used the method in optimizing plant additives one at a time and drawing on ber of variables tends to be much larger
operations for chemical manufactur- their previous experience. They enter and the research can be at a much ear-
ing. In the plant, he used DOE to un- the results of their lab tests into the DOE lier stage, a three-step process is used:
derstand product quality, capacity and program and run a screening analysis to screening, identifying correlations and
impurity levels: I can dial things up or see which additives have the strongest formula optimization. For his purpos-
down, he says. Fluid formulations are benecial effects on overall uid prop- es, however, he nds it more efcient
different, though. If youre developing erties. Additives that affect the results to combine the correlation analysis and
a mixture, you cant just keep adding very littleor that have a negative ef- formula optimization into one step.
stuff. The components are not entirely fectcan be eliminated from further Hoon Kim, senior principal R&D
independent, and the formula composi- consideration at this point. The initial scientist at Chemetall, a part of BASF
tion must add up to 100%. screening run also gives an indication Group based in New Providence, N.J.,
In developing formulations, his- of which parameters are the most effec- develops new metalworking uid prod-
torically, you would use trial and er- tive ones to optimize. The results of the ucts with an emphasis on uids for use
ror; you would test everything, Trauth initial screening run narrow the problem with aluminum. He spends about half
says. But it was hard to tell whether the down to a manageable set of variables. his time developing formulations and
differences you saw were real or due to Once the analysis of the screening the other half developing new additive
measurement errors. Once you start run is complete, Trauth says the de- technology. Part of the new additive
adding components, the number of veloper denes an objective function technology work addresses environ-
variables gets very large very fast, he to use in the optimization run. This is mental issues like nding replacements
says, noting that testing eight variables where the developers main goal comes for chlorinated parafns.
42 Point 6: Use training on the job. Train for consistency to reduce variation and build a foundation of common knowledge.
Kim uses a similar two-step DOE
^d
process. Screening lets us look at
multiple factors (more than six, say)
and see which ones have the strongest
effects. If were only studying two or
three factors, we sometimes skip the
screening and go right to the predic-
tive analysis, he says. Predictive DOE
is where he takes the most inuential Figure 3 | DOE analysis is used to optimize the concentration of uid additives. Here the ef-
factors, nds the correlations between fects of varying the concentration of an anti-staining additive are validated using aluminum
them and builds his model. This is alloy test strips. (Figure courtesy of Hoon Kim, Chemetall.)
where he does the optimization work.
Kim also emphasizes the importance of
setting parameter limits and specifying
a goal for the optimization in terms of
cost, performance or some other crite- Property Control: EP vs. LE vs. PP vs. Lubricity
rion. The computer nds an optimal
formulation based on those criteria,
he says.
Specialty chemical companies might
skip the screening altogether, Kim says,
since they produce individual chemi-
cals and are mainly interested in opti-
mizing the production process. Fluid
formulators, on the other hand, are
dealing with multi-component sys-
tems, and they need to narrow the fac-
tors they study to keep the number of
experiments manageable.
Kim and his colleagues have used
DOE for a variety of projects. For ex-
ample, they developed a new metal-
working uid formulation using 40
lab screening experiments as input to
the DOE program to come up with the
one nal formulation. We would have Figure 4 | Multivariate plots show the linear correlations between multiple variables simulta-
had to test hundreds of formulations neously. Elongated elliptical shapes indicate a strong correlation between variables, while a
otherwise, he says. broad round ellipse means a weak or no correlation. Here mixture design DOE was used to
In another study, they compared the evaluate the lubricity performance of two new lubricity agents (EP and LE) compared to the
anti-staining properties of a uid addi- current technology (PP). Only EP shows positive correlation with lubricity on steel (yellow
tive on aluminum alloys (see Figure 3). squares). Parameter estimates from the DOE indicated a potential synergistic interaction be-
tween EP and LE on aluminum (blue squares). This result indicates that the new EP and LE
After the initial screening tests, DOE
technology can improve the lubricity performance of the current formulation. (Figure courtesy
helped them optimize the concentra-
of Hoon Kim, Chemetall.)
tion of the additive to provide the best
stain protection without compromising
the overall uid performance.
Kim also cited the example of a new
extreme pressure (EP) additive tech- DOE recommended in the lab, and it ena and physical property databases
nology that his group developed (see works! he says. The computer gener- into their analyses, but DOE analysis is
Figure 4). They used DOE to see which ated the formulation, not us! rmly based in laboratory testing. You
chemistries were most effective at im- have to set up the screening, and that
proving lubricity. We put in all the EXPERIENCE STILL COUNTS requires knowledge, says Trauth. The
data and the computer came up with DOE doesnt do the science for you, DOE provides the math to help you ar-
the best formulation, Kim says. They however. Software packages like Aspen rive at conclusions. Manufacturers cant
validated the optimal formula that the incorporate known physical phenom- make huge changes in the plant or try

out every possibility, so DOE lets you DOE is more efcient, he adds. They used automated analysis to run
extrapolate from your initial screening Experience also is valuable for get- hundreds of tests, but it turned out
tests, he adds. ting a feel for what should work and that DOE was better at producing the
Experience is helpful in picking a knowledge of what just doesnt work, needed information.
set of variables for initial screening, but Trauth says. At a former job, his em-
it really comes into play when its time CASE STUDY:
to interpret the results and begin to op- A TALE OF THREE ADDITIVES
timize a process or formulation. Look Zhao and his colleagues used DOE to
at the error bars; how much uncertain- examine the effects of various additives
The DOE provides
ty is in the results? asks Trauth. This is on soluble oil cutting uid emulsions.
a good indicator of whether results are the math to help you Their objectives included improving
signicant or merely a result of experi- arrive at conclusions. emulsion stability in very hard water,
mental uncertainty. If the experimental reducing the tendency to foam and
error is too large to derive a meaning- maintaining good blooming (emulsion
ful result, thats when you do a second spreading) characteristics.
set of DOE calculations over a tighter ployer tried using high-throughput They compared three nonionic
range. If its really cheap and fast to do research. This approach, in which you surfactants, each having a different
the experiment on the y, then another use automated lab analysis instruments hydrophile-lipophile balance (HLB,
set of lab tests can provide clarity, but to test every possible permutation, is a measure of a surfactants ability to
if it takes a signicant amount of time the opposite of DOE, which seeks to form emulsions) to see if high-HLB
or effort to do the experiment, then narrow down the number of variables. surfactants caused more foam. For the
Emulsion Blooming Test Results
Figure 5 | Results of an emulsion blooming test using nine combinations of three additives (top table shows mixture compositions). Formula 2
formed an emulsion that quickly reached the bottom of the cylinder. Formulas 3 and 6 only formed emulsions in the top 2/3 of the cylinders. The
travel distances for each sample (bottom rows of the table) were used in the DOE analysis to nd correlations between additive combinations
and blooming distances. (Figure courtesy of Philip Zhao, Houghton International, Inc.)
Point 7: Implement leadership. Dont simply superviseprovide support and resources to staffers. Be a coach, not a policeman. 45
Emulsion Stability Test Results by Turbiscan
ZW^
&^q
Figure 6 | Turbiscan results for the group of samples shown in Figure 5. High backscattering intensities (BS%) indicate less breaking up of the
emulsion. After 25 hours, signicant changes are apparent in the emulsions at 50 C. Formulas 5 and 6 showed the least amount of change, in-
dicating that the high-HLB emulsier improves the stability of the emulsion. (Figure courtesy of Philip Zhao, Houghton International, Inc.)
Results of Foam Tests and ANOVA
dd/^
Figure 7 | Analysis of variance (ANOVA) on the results of foam tests shows that all of the p-values are less than 0.05, indicating that all three
emulsiers and all of their combinations signicantly affect the foaming properties of the hard-water emulsions, either increasing or decreasing
the tendency to foam and the stability of the foam. (Figure courtesy of Philip Zhao, Houghton International, Inc.)

ever, it turned out not to be a signi-
cant improvement) and the low-HLB
mixture worsened.
After doing a DOE optimization
run to balance the effects of emulsier
HLB on blooming, emulsion stability
and foam (see Figure 8), the Houghton
team devised an optimal formulation
that was signicantly better than their
control formula (see Figure 9). This for-
mulation was then validated in the lab
(see Figure 10 on Page 48).
Figure 8 | DOE helps developers select the optimization parameters that have the greatest
effect on a uids performance. They enter concentration ranges for each additive into the GETTING STARTED
factor section and the desired ranges of specic properties into the response section. The
Unlike the pioneers of DOE, todays u-
upper and lower weights and the importance values shown here are default values for the DOE
id developers dont need to be experts
program, but these could be adjusted as well. (Figure courtesy of Philip Zhao, Houghton Interna-
tional, Inc.) in statistics to use the methods effec-
tively. However, they still need a basic
knowledge of statistical principles and
the ability to see what the results mean.
Learning to use DOE is like learning
to drive a car, says Kim; in the begin-
ning, youre nervous. But once you get
comfortable using the car, it can take
you a long distance very quickly. You
dont need to know everything about
the car or how to build one to be a
good driver. But it still requires some
skill from the driver.
Anyone wanting to get started with
DOE should check the software vendor
Websites, Kim recommends. The ven-
dors offer free tutorials on their Web-
sites that are very detailed. You can go
to training sessions geared to your level
of experience, he says.
Zhao recalls, I only had one stats
Figure 9 | The DOE software arrived at a formulation that produced the best combination of
course in college, and I still remem-
blooming distance, foam dissipation and emulsion stability. (Figure courtesy of Philip Zhao,
Houghton International, Inc.) ber a few basics, but you dont need
much. Over the course of his career
he has used three software packages.
Some software is more powerful but
screening phase of the DOE, they com- optimal formula. difcult to use, and some software as-
pared nine formulations by injecting Analysis of variance (ANOVA) test- sumes that you are familiar with more
cutting uid concentrate into hard wa- ing from the DOE program showed technical terms. Dont be afraid to use
ter and recording the emulsion travel that the medium-HLB emulsier sig- the software, but do get the training,
distance with time, using a Turbiscan nicantly improved blooming, the low- he recommends.
instrument (see Figure 5 on Page 45). HLB emulsier made it signicantly Zhao says that with training, you
They also compared the stability of the worse and the high-HLB emulsier learn to interpret the results. On a ba-
emulsions over a 25-hour period (see had no statistically signicant effect. sic level, you can examine p-values
Figure 6) and the foaming properties of The analysis also showed that mixing and make sure that they are less than
each emulsion (see Figure 7). They en- either the medium-HLB or low-HLB 0.05. This typical cutoff point tells you
tered the results into the DOE program emulsier with the high-HLB emulsi- theres at most a 5% probability that
to nd correlations between formula- er produced synergistic effects: the the differences youre seeing are caused
tions and properties and to generate an medium-HLB mixture got better (how- by experimental error or uncertainty.

(Put another way, theres at least a 95% Trauth is one of two resident DOE of information and advice. Often,
chance that the differences youre see- experts at ANGUS, but even so, they these tech support staffers are experts
ing are real.) Even if a correlation is rely on help from the companys soft- in a particular eld, and they have a
what you want, if its not statistically ware tech support people. Most of his deep knowledge of the software and
signicant, dont use it or re-examine experience is in using DOE for manu- its applications. In addition, they
it, Zhao says. facturing processes, but now he works gain experience from working with
If you dont know what youre do- with uid formulators as well. He re- several client companies on their ap-
ing, statistics can lead you astray, says calls that there was some resistance at plications. Although they cant share
Trauth. I took a stats class in college rst to using DOE for formulations. specic information between compa-
and used statistics in grad school and in The thinking was, if you stay out of nies, they are likely to know how to
my career. Six Sigma really got me into the stats box you can be more creative, deal with certain situations, drawing
it, he says, referring to his time at Dow he says. Part of this was a tendency on on this experience.
Chemical Co. When I started, we didnt the part of company chemists to look Software vendors also sponsor user
do much DOE, but Dow went in really for big changes, but his experience as groups and forums, online and at con-
big for Six Sigma (a set of management an engineer taught him that small but ferences, where users can share their
practices aimed at reducing inefciency signicant improvements can add up to know-how with one another. This is
and errors to an absolute minimum.) substantial cost savings. especially helpful in smaller operations
This effort included a lot of statistical Kim, Trauth and Zhao all noted where there might not be an opportu-
analysis, and employees received training that the software vendors tech sup- nity to do this kind of sharing in-house.
in the processes and methods, he says. port people were an important source For example, Kim is the only person
K
& &
K&/d&
Figure 10 | Lab tests validate that the optimal formula produced by the DOE analysis performs as well as or better than the control formula for
blooming properties (left), resistance to foaming (top right), and emulsion stability (bottom right). (Figure courtesy of Philip Zhao, Houghton In-
ternational, Inc.)
48 Point 8: Eliminate fear. Use open and honest communication to remove fear from the organization.
in his group to use the JMP software AN EMERGING CAPABILITY community. Fluid formulators are start-
package. I make use of JMPs on- Software and statistics are all very well ing to use it more often, but its still
line user community, he says. They and good, but can statistical DOE help not commonly used. This is a mature
have blogs and online information ex- you improve formulations in the real eld, he says, and senior people would
changes where more than 8,000 mem- world? rather trust their own experience. But
bers interact. They also sponsor live Trauth says that ANGUS Chemi- once they see what DOE can do, they
conferences called Discovery Summits cal makes four compounds, and sales see that it works, he says. I want to
that are forums for users to share their for one of them grew faster than for see more people use DOE!
experience and give presentations on any of the others. You want to make
how to use the software for various ap- more of what sells, he says. The reac-
plications. tion that made the compound was very REFERENCE
Zhao and Trauth arent as involved exothermic, and it was hard to control 1. A Quick History of the Design of
in software user communities, but they the temperature and pressure. DOE let Experiments (DOE), STAT 503:
Design of Experiments, Penn
do make use of their own companies Trauth and his team optimize the reac-
State Eberly College of Science.
in-house tech support staff as well soft- tion conditions. They came up with a
Available at https://onlinecourses.
ware companies tech support staff. model that showed they could control science.psu.edu/stat503/node/6.
They recommend the workshops that the temperature more easily if they used
the software companies sponsor as the dilute rather than concentrated nitric
best place to begin DOE training. Some acid in the reaction. His colleagues were
of this training is online in the form skeptical, but it worked beautifully!
of tutorials and webinars, and some is He adds, DOE can open up spaces you Nancy McGuire is a free-lance
offered in person. Larger companies wouldnt imagine would work. writer based in Silver Spring, Md.
might have in-house user groups and Kim notes that DOE is an emerging You can contact her at
training as well. technique in the metalworking uids nmcguire@wordchemist.com.
2017 PerkinElmer, Inc. All trademarks or registered trademarks are the property of PerkinElmer, Inc. and/or its subsidiaries.
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2018 STLE
Tribology Frontiers
Conference
Oct. 28-31, 2018 Chicago
Co-sponsored by ASME Tribology Division.
Message from the Chair After the TFC debuted in Chicago in Harman Khare, University of
Dr. David L. Burris 2014, STLE held TFCs in 2015 and Pennsylvania
2016. While STLE is not presenting Ashlie Martini, University of
Dear Industry Professional, the TFC this year, as we are partner- California-Merced
ing with the Chinese Tribology Insti-
Marketing gurus say the best way to tute on the 2017 World Tribology Con- Robert Jackson, Auburn Univer-
promote any product is with a free gress next month in Beijing, we will sity
sample. In that spirit, the 2018 Tri- again present the TFC in October Perter Jacobs, ExxonMobil
bology Frontiers Conference Plan- 2018. Were returning to the historic
Tevis Jacobs, University of
ning Committee is partnering with Drake hotel in downtown Chicago,
Pittsburgh
TLT magazine to present a new fea- site of 2016s successful TFC and a
ture2016 TFC Highlights. city thats easily reached from any- Bart Raeymakers, University of
where in the world. Utah.
These papers were chosen by a com-
mittee comprised of some of our most Registration for the 2018 TFC opens Enjoy the abstractsand Ill see you
distinguished and well-respected col- after the 73rd STLE Annual Meeting & in Chicago in October 2018.
leagues in tribology research. We then Exhibition in Minneapolis next May.
asked the authors of those papers to Youll be able to access the TFC tech- David
create abstracts of their work. Start- nical program, register for the event
ing with this issue, youll see these and reserve your room at the Drake
abstracts monthly in TLT until the at www.stle.org.
2018 TFC.
I would like to extend my sincerest
The TFC differs from other tribology- thanks to the TFC Highlights Selection
research conferences in that we have Committee for selecting the papers that
a very specic theme. All research is will be abstracted and published in TLT:
aimed at discovering the role tribology
will play in solving tomorrows most Gary Doll, University of Akron
critical technical, environmental and Benjamin Gould, Argonne
societal problems. National Laboratory

2016 TFC HIGHLIGHTS
Shining a light on the tribological

rehydration of cartilage
Axel C. Moore, Brian T. Graham, Chris Price, David L. Burris

University of Delaware
Cartilage exudes interstitial uid and metabolic waste prod- speed dependent; solute uptake in the center of contact was
ucts during loading and recovers interstitial uid and nu- only signicant at 60 mm/s, which is near physiological slid-
trients from the synovial uid during articulation through ing speeds (100-150 mm/s). The results suggest that uid
mechanisms that remain unclear. Here we illustrate a fun- entrained at the leading edge of contact is pressurized and
damentally new and unanticipated mechanism of uid and subsequently forced back into the porous articular surface to
nutrient uptake by articular cartilage. During sliding follow- restore hydration, thickness, nutrition and lubrication. While
ing static loading against glass (inset A), simultaneous com- inactivity is associated with dysfunction and disease due to
pression and friction reduction provide strong but indirect exudation, these results suggest that regular physical activity
evidence of sliding-induced uid recovery, which we call tri- promotes long-term joint health because tribological rehy-
bological rehydration. An in-situ solute absorption assay was dration counteracts the detrimental effects of the exudation
used to test this hypothesis (inset B). The penetration of the process on the mechanical, tribological and biological func-
1nm diameter solute into the buried contact area was strongly tions of cartilage.
Point 9: Break down barriers between departments. Use cross-functional teamwork to build understanding and reduce adversarial relationships. 51
PEER-REVIEWED
Optimization of Mechanism of Boundary

Lubrication in Fully Formulated Commercial
Engine Oil Using Design of Experiment
GABI N. NEHME and MICHELINE DIB
Department of Mechanical Engineering
University of Balamand
ElKoura, Lebanon
ABSTRACT
Manuscript received May 3, 2010
Manuscript accepted Oct. 23, 2010 Design of experiment (DOE) analysis was used to study the desirability factor between
Review led by Elaine Yamaguchi contact loads, oil quantity, and surface roughness. The analysis developed a series of
STLE interactions between factors to get the best correlations between contact loads and oil
quantity that leads to the stabilization of the tribolm. A closed-loop boundary condition
test was developed to examine the behavior of lubricants under boundary conditions.
Polished and unpolished testing specimens were established to show the differences in
friction and wear proles under extreme boundary lubrication. The boundary condition
test was very reproducible and can be used to study the mechanism of boundary lubrica-
tion. The mechanism of antiwear lm formation and breakdown was followed carefully
by monitoring the friction coefcient over the duration of the test and running scanning
electron microscopy (SEM) on selected tests. The thickness of the boundary layer lubri-
Editors Note: This months cant, which is determined by the concentration of additives in the supplied oil, is optimized
Feature article discusses the for the polished and unpolished test cylinders. The optimized desirability shows the best
benets of design of experi- loading and oil supply condition that leads to greater consistency in the breakdown of the
ment (DOE), so it only seems tribolm for a xed contact load and xed amount of fully formulated zinc dialkyldithio-
tting that this months phosphate (ZDDP) oil. The number of cycles to breakdown of the protective tribolm is
Editors Choice paper be an also consistent with the applied load for a xed thickness of the boundary lubrication lm.
example of DOE. The princi- It is evident that at lower contact loads a stable tribolm rich in phosphorous is formed,
pal author of this paper has whereas at higher contact loads the breakdown of the tribolm results in wear debris and
several other papers relating higher sulfur content on the wear surface.
to DOE published in Tribology
Transactions. What made this KEY WORDS
particular paper interesting Boundary Lubrication; Tribolm; Wear; Surface Roughness; DOE; SEM; EDX
was how well DOE was able to
reduce the need for time-con- INTRODUCTION
suming studies in identifying The lubricant in an internal combustion engine serves several purposes, such as
the optimal load conditions maintaining fuel economy, reducing wear, and providing corrosion protection (So
that formed a stable tribolm, and Lin (1)). The Stribeck curve is extensively used to illustrate the three regimes of
which resulted in less wear. lubrication, which include elastohydrodynamic (EHD), mixed, and extreme pressure
(EP) regions. Under low loads and/or high viscosity and high speed, the separation
Evan Zabawski, CLS of the contacting surfaces is large enough relative to surface roughness that the coef-
Editor cient of friction is determined by the uid properties of the lubricant in the elas-
tohydrodynamic region of the lubrication. As load increases and/or speed decreases

Optimization of Mechanism of Boun
coupled with lower oil (lubricant) viscosities, contact between

surfaces can occur where the friction coefficient increases in TABLE 10.1 P% COMMERCIAL OIL COMPOSITION steel r
the extreme pressure region. Chemistry Methodology Composition (ppm) ken C
The interaction of lubricant with a solid surface results in the rin
Sulfur ASTM D3120 (11) 2,637 ter M1
the formation of a boundary layer with distinct physical and
Zinc ASTM D5185 (11) 1,002
chemical properties from the antiwear film formed in fully to rem
Phosphorous ASTM D5185 (11) 1,009
bathed oil. The transfer film was formed as a consequence cylinde
Silicon ASTM D5185 (11) 12
rangin
of the interaction of the lubricating medium with the metal Copper ASTM D5185 (11) 6
Sodium ASTM D5185 (11) 24 3 to 5
surface. In boundary lubrication, variation of friction coef-
Boron ASTM D5185 (11) 122 1,500-g
ficient, hardness of the rubbing surfaces, chemical reaction
Calcium ASTM D5185 (11) 2,450 5 N us
film formation, nature of the boundary lubricating film, and remov
Magnesium ASTM D5185 (11) 18
oxidative degradation under tribocontact play an important Molybdenum ASTM D5185 (11) 81 paper
role in the test outcome (Sheasby, et al. (2); Bell and Richards Cadmium ASTM D5185 (11) 2 roughn
(3); Gates, et al. (4); Sukirno (5)). 0.2 an
The commercial fully formulated oil used in the experi- four balls on a cylinder (Sheasby, et al. (12)), which contributed 3.75
ments contained 0.1% P zinc dialkyldithiophosphate (ZDDP). greatly to the scientific understanding. The
It has been reported (Barnes, et al. (6)) that the main func- The antiwearinfilm
concentrations at the optimized
selected surface boundary during the
tests. Surface startup
roughness, chosen
tion of ZDDP is to prevent wear between surfaces and retard of anand
load, engine is very important
oil volume supplied because
were analyzedmost of as thefactors
wear in an
using the su
oxidation of the lubricating oil. The strength of the boundary engine occurs
two-level during
factorial this stage
design when a thin layer of lubricant
of experiment. carefu
film depends mainly on the decomposition of ZDDP and the coupled with a preexisting
The experiments weretransfer
processedlayer or intribofilm is the onlyas
two replicates and th
formation of polyphosphate products (Smith (7)); such prod- protection from metal-on-metal contact.
shown in Table 2 on Page 54. Lubrication under extreme The effectiveness of then w
boundary lubrication is dependent on many variables, includ- of oil
ucts are Zn (Fe) phosphate and Zn/Fe sulfides/oxides. The loading of 297405 N (corresponding to a Hertzian contact
ing concentration of additives in the supplied oil, load, and sur- bound
thickness and length of the chains forming the antiwear film is pressure of 2.52.77 GPa) and a limited quantity of oil were
face roughness. The primary antiwear agent used in engine oils and 75
complicated by lubricant chemistry, thermal effects, dynamic used to simulate the boundary conditions. The objective of
is ZDDP, and its decomposition was detailed in previous stud- A1
loading, speed, temperature, and material effects (Barkshire, this article is to develop a new closed-loop test method to
ies (Armstrong, et al. (13); Willermet, et al. (14); Yin, et al. (15); body.
et al. (8); Ma, et al. (9)). study
Spikesthe effect
(16); of contact
Martin, load
et al. (17); Cao,with respect
et al. to the et
(18); Barnes, optimized
al. (19); to ensu
Different test techniques have been previously applied to oil volume. The analysis provides a clear difference
Smith, (20); Coy and Jones (21)). The thickness and coverage from other
of ing of
evaluate boundary testing. Many test methods have been em- methods
these filmsbecause it uses DOE
on the boundary layer statistics
is important to in
optimize
determining and the
test and th
ployed to evaluate boundary lubrication, such as spinning ball the
wearfinal condition
resistance of boundary
of the the polished layer and unpolished
(Barkshire, et al.tests,
(22)).in ad- contro
on disk with direct observation (Sheasby, et al. (10)), pin on dition to characterizing
In this study, design oftheir chemistry
experiment (DOE) under the optimized
software was used has a h
disc, and four balls on a cylinder (Sheasby, et al. (12)), which loading
to optimizeand the
volume
volume of oil conditions
of fully formulated usingcommercial
EDS coupled with
oil with der, th
contributed greatly to the scientific understanding. respect to surface
X-ray of the wear track. finish and contact load. Commercial oil chem- the He
The antiwear film at the surface boundary during the istry and concentration of additives are provided in Table 1. The inert a
startup of an engine is very important because most of the EXPERIMENTAL
role of the lubricant PROCEDURE
volume and contact load was optimized, Instea
wear in an engine occurs during this stage when a thin layer and scanning electron
A Plint T53 Slim modified microscopy (SEM) coupled
ball-on-cylinder with energy-
machine (Phoe- came f
dispersive spectroscopy (EDS) and X-ray of the wear tracks were come f
of lubricant coupled with a preexisting transfer layer or tri- nix Tribology, Whitway, UK) was used for all tests. An SAE
used to indicate the existence of additive concentrations in se- surface
bofilm is the only protection from metal-on-metal contact. Timken steel ring (6466 Rockwell C Hardness [HRC], 60
lected optimized tests. Surface roughness, load, and oil volume The
The effectiveness of boundary lubrication is dependent on mm OD, Tim ken Co, Irving, TX) was the moving body. The
supplied were analyzed as factors using two-level factorial design test in
many variables, including concentration of additives in the surface finish of the rings was examined using a profilom-
of experiment. plied.
supplied oil, load, and surface roughness. The primary anti- eterThe
(Mahr Perthometer
experiments were M1, Akron,
processed OH).
in two The cylinders
replicates as shown were
in drople
wear agent used in engine oils is ZDDP, and its decomposi- cleaned with acetone to remove any machining
Table 2. Lubrication under extreme loading of 297405 N (corre- oil that was with a
tion was detailed in previous studies (Armstrong, et al. (13); present.
spondingThe to a as-received
Hertzian contact cylinders
pressure hadofinconsistent
2.52.77 GPa) surfaces
and a was ha
Willermet, et al. (14); Yin, et al. (15); Spikes (16); Martin, et with Ra quantity
limited or surface of roughness
oil were used ranging fromthe
to simulate 0.2boundary
to 0.4 mcon- and a unifo
al. (17); Cao, et al. (18); Barnes, et al. (19); Smith, (20); Coy asperities
ditions. The Rzobjective
height ranging from 3is to
of this article to 5 m. Some
develop a newcylinders
closed- dead w
and Jones (21)). The thickness and coverage of these films were
loop subsequently
test method topolished
study theusingeffectaof1,500-grit
contact load polishing
with respectpaper tered i
on the boundary layer is important in determining the wear to the
for 5,000optimized
cycles atoil700
volume.
rpm Theat a analysis
load of 5provides
N usinga neutral
clear differ-base Re
resistance of the boundary layer (Barkshire, et al. (22)). ence from other methods because it uses DOE
oil as a lubricant. The cylinder was then removed and ultra- statistics to opti- test wa
In this study, design of experiment (DOE) software was mize and test
sonicated the final to
in acetone condition
removeofthe thepolishing
polished and unpolished
paper abrasive mixtur
used to optimize the volume of fully formulated commercial tests, in addition to characterizing their chemistry
and neutral base oil. After cleaning, the surface roughness under the op- specim
oil with respect to surface finish and contact load. Commercial timized loading and volume of oil conditions
was measured to ensure that the Ra ranged between 0.2 and using EDS coupled Postte
with X-ray of the wear track. sured u
oil chemistry and concentration of additives are provided in 0.25 m and the average Rz range was between 3 and 3.75 m.
a JEO
Table 1. The role of the lubricant volume and contact load was The amount of PROCEDURE
EXPERIMENTAL oil used in the boundary lubrication tests
mode
optimized, and scanning electron microscopy (SEM) coupled was chosen to simulate conditions that exist when oil has
A Plint T53 Slim modified ball-on-cylinder machine (Phoenix To
with energy-dispersive spectroscopy (EDS) and X-ray of the drained from the surface. Cylinders were cleaned with acetone
Tribology, Whitway, UK) was used for all tests. An SAE Timken gather
wear tracks were used to indicate the existence of additive and weighed carefully. They were dipped in engine oil for a

TABLE 2DATA FOR THREE FACTORS AND TWO RESPONSES INCLUDED IN THE ANALYSIS
Order of Tests, Factor # 1, Factor # 2, Factor # 3, Surface Roughness
Two-Level Factorial Oil Quantity Load (Intermediate vs. High) (Polished vs. Unpolished),
and Two Replicates 4080 L 297405 N 0.20.25 m Ra vs. 0.20.5 m Ra
1 40 297 Unpolished
2 40 405 Unpolished
3 80 405 Polished
4 40 297 Polished
5 80 405 Unpolished
6 80 297 Polished
7 80 297 Unpolished
8 40 297 Unpolished
9 80 297 Polished
10 80 405 Unpolished
11 80 405 Polished
12 40 405 Polished
14 40 405 Polished
15 40 297 Polished
Order of Tests, Response # 1, Response # 2,

Two-Level Factorial and Two Replicates Wear Depth (m) Number of Cycles to Failure
1 7.71 54,800
2 21.51 9,900
3 11.22 28,500
4 5.2 95,500
5 15.42 20,300
6 2.51 100,000
7 3.81 95,100
8 7.35 53,000
9 2.55 100,000
10 16.0 19,100
11 11.67 29,200
12 19.35 15,200
13 3.62 94,300
14 18.91 15,800
15 5.31 97,000
16 20.88 10,600
period of 15 min and then laid out on an absorbent paper for act with the lubricant to form a tribolm. Instead, a transfer
a period of 12 h and then weighed again. The difference in lm formed on the surface of the ball, which came from the
weight yielded the amount of oil that was present in the form ring surface. Hence, we examined only the outcome from the
of a thin layer to make the boundary lm. The amount of oil interaction of the lubricant with the steel cylinder surface at
was found to be between 50 and 75 L. conditions of the test.
A 12.5-mm tungsten carbide ball (79 HRC) was the coun- The cylinder and tungsten carbide ball were mounted on
terbody. A tungsten carbide ball was chosen as the counter- the test instrument and a measured quantity of desired oil
surface to ensure that the wear occurred on the test cylinder. was applied. A medical-grade syringe was used to dispense
The annealing of the steel ball at the contact point resulted oil in microdroplets of 55 L at the contact point of the ball
in extensive wear and the subsequent reduction of Hertzian and cylinder with a load of 4.7 N applied. The shaft holding
contact load was not controlled. With the use of a tungsten the test cylinder was hand rotated while the oil was being
carbide (WC) ball, which has a hardness of 15 Rockwell C applied to ensure that a uniform quantity was applied on the
higher than the underlying cylinder, there was little or no contact area. The desired dead weights were placed on the
wear on the ball, essentially keeping the Hertzian contact load lever. Test conditions were entered in the software and the
constant. In addition, the WC ball was inert and did not inter- test was conducted at 700 rpm.
54 Point 10: Get rid of unclear slogans. Excellence in Service is short and memorable but what does it mean? How is it achieved?
Required test data were gathered in real time and after the
test was completed the ring was washed with a hexaneac-
etone mixture to remove the debris and oil from the surface.
The wear specimens were stored in vacuum desiccators to
prevent rust. Posttest analysis was then carried out. The wear
prole was measured using the prolometer, and the surface
was examined using a JEOL JSM 845 SEM operating in sec-
ondary electron imaging mode coupled with EDS (Joel USA
Inc., MA).
To minimize experimentation processes and optimize the
gathered data for various responses, a useful tool is DOE ap-
plied to the analyzed factors and responses. The model was
used to optimize the important responses such as wear depth
and number of cycles to failure for specic ranges of load and Figure 1 | Explanation of the frictional events of three consistent
oil quantity, which can be justied during the verication of polished tests in boundary lubrication: (A) beginning of the test and
these experiments for both polished and unpolished surfaces. the run-in process, (B) steady-state friction, (C) onset of scoring, (D)
The justication was based on the model signicance and reactivation of antiwear lm and healing process, (E) steady-state
its desirability (Appendix A). Due to space limitations, full friction after the healing process, and (F) steep rise of friction and
details of the statistical analyses are not included, such as failure.
optimization of wear depth and number of cycles to failure
for all ranges of oil quantities and loads. This information is temperature, which results in the further breakdown of ZDDP
available from the rst author.1 and the reestablishment of a protective antiwear lm. The
In order to calculate the thickness of the lubrication lm, formation of this protective lm results in the decrease in the
four models of the lm thickness, including the Grubin equa- coefcient of friction as shown in region D. The reformation
tion, the Dowson-Higginson equation, the Archard-Cowking of the stable lm results in a stable steady-state coefcient of
equation, and the Hamrock-Dowson equation were consid- friction as shown in region E. The breakdown of the protec-
ered (Grubin (23); Dowson and Higginson (24); Archard and tive lm results in abrasive wear, resulting in a rapid increase
Cowking (25); Hamrock and Dowson (26)). Detailed calcula- in temperature and coefcient of friction and eventual burn-
tion was estimated applying the method used by Mourhatch, off of the lubricant. This breakdown region is region F. The
et al. (27). duration and failure of the test depend greatly on the nature
of the protective antiwear lm, amount of lubricant additive
RESULTS AND DISCUSSION used, and applied load.
Mechanism of Boundary Lubrication
Figure 1 represents three replicates of three polished tests Reproducibility of the Boundary Lubrication Tests
under extreme boundary lubrication. These tests were very Boundary lubrication occurs under conditions of extreme
reproducible and show the frictional events that occur during stress and/or insufcient lubrication. Starved oil conditions
a typical boundary lubrication test. The early stages of the test can easily mimic the boundary lubrication conditions because
process marked as A are largely abrasive due to the wearing a major portion of the load is supported not by the oil lm
of the asperities on the surface of the cylinder because an an- but by the solid contact including the tribolm (Gates, et al.
tiwear protective lm has not been formed yet. The duration (4); Sukirno (5); Gates and Hsu (30)). In order to study the
of the phase for the antiwear additives ZDDP to break down boundary lubrication, typical tests were conducted as part of
and form a protective layer is approximately 5001,000 rota- DOE to simulate and optimize conditions at the point of con-
tions. The stable antiwear lm formed at the end of stage A is tact. A closed system was chosen where a specied amount
responsible for the steady-state friction behavior in region B, of oil was applied to the contact surface and the boundary
where there is dominance of the benecial effects of tribolm lubrication has to be provided by the limited antiwear addi-
formation. The stable tribolm has been shown by several tive concentration in the supplied oil. Number of cycles to
earlier studies to be composed of polyphosphate chains, Fe, failure and wear depth were used in the DOE as responses
and suldes and sulfates of zinc (Mourhatch and Aswath (27); (Table 2) to optimize loading and oil volume for polished
Rounds (28); Willermet, et al. (29)). The duration of stage and unpolished testing conditions. All polished tests were
B is a strong function of several factors, which include the very reproducible and some inconsistencies were found in
amount of lubricant, surface roughness, and the applied load. the repeatability of the unpolished tests.
These factors will be used in DOE analysis to optimize the DOE is the simultaneous study of several variables. By
condition of multiple experiments. When the protective lm combining several variables in one study instead of creat-
breaks down, there is a steep rise in the friction coefcient as ing a study for each, the amount of testing required will be
shown in stage C. The rise in friction corresponds to higher drastically reduced and greater process understanding will

Figure 2a | Number of cycles to failure vs. oil quantity at 297 N loading.
Figure 2c | Wear depth vs. oil quantity at 297 N loading.
Figure 2b | Number of cycles to failure vs. oil quantity at 405 N loading.
result. This is a direct contrast to typical one-factor-at-a-time

(OFAT) studies, which limit the understanding and waste
data. The DOE methodology spans a wide range of analytical
approaches developed for different situations or nal targets. Figure 2d | Wear depth vs. oil quantity at 405 N loading.
Figures 2a and 2c show the number of cycles to failure and
wear depth responses for the polished and unpolished tests
under a 297 N load (Hertzian contact pressure of 2.5 GPa). the model based on the percentage probability and the effect
They indicate an increase in the number of cycles to failure charts where interactions between factors are increasingly sig-
and decrease in the wear depth as the volume of oil containing nicant. Wear width was rejected from the analysis because
ZDDP additives increases. Figures 2b and 2d show the same the percentage probability vs. effects showed no signicant
responses under different loading condition (405 N). These interactions. The nal decision outcome of the DOE relied
gures indicate an improvement in wear and failure time in on the number of cycles to failure and wear depth, where
the polished surfaces over the unpolished ones. optimization of loading conditions and oil volume are re-
A two-level factorial design was used as part of a DOE quired. An example of number of cycles to failure and wear
analysis to optimize the wear depth and number of cycles depth interaction graphs for polished and unpolished surfaces
to failure with respect to fully formulated oil volume and with respect to oil quantity and specic loads are shown in
loading conditions using polished and unpolished surfaces. Figure 2.
There were three factors in the DOE and the tests were run In this study, the model F-value related to wear depth and
with two replicates for better consistency. Therefore, 16 ex- number of cycles to failure was very signicant, along with
periments were used for the DOE analysis. The DOE soft- the specied interactions (as shown in Appendix A, Figures
ware ran the analysis simultaneously for all factors and re- A1 and A2, Tables A1 and A2) of the analysis of variance
sponses considered in the model. Evaluation of each response (ANOVA) output and the half normal plots. In these ANOVA
and the percentage probability vs. effects were investigated tables there is a only a 0.01% chance that a model F-value this
for all responses including the wear width response. Wear large could occur due to noise for the wear depth response
depth and number of cycles to failure contribute largely to and for the number of cycles to failure response.

The model is a reection of two responses and three fac-
tors. We cannot choose an increased numbers of cycles to
failure at the expense of wear depth. For higher desirability
we should look at the best load, oil volume, and surface nish
that can give us higher number of cycles to failure with mini-
mum wear depth. These were manipulated in DOE analysis
and optimization using the desirability function.
Desirability is used when multi-objective optimization
is sought according to Derringer (31) and Barrentine (32).
According to this approach, each response has to be con-
verted into a corresponding desirability function. The desir-
ability is high when the response approaches its target value.
Common goal types are target within range, minimum, and
maximum. Each is linked to its own desirability function.
So desirability will indicate, based on the model optimum
loadings and oil volumes, a good number of cycles to failure
coupled with minimum wear depth. Therefore a good desir-
ability is achieved when the responses and factors interactions
are optimized. In short, the desirability is based on what you
are targeting in the model when you evaluate your responses
before optimization; we are targeting maximum number of
cycle to failure and minimum wear depth with respect to load-
ing conditions and volume of oil. The desirability established
by the model presents a clear improvement when the polished
surfaces are compared to the unpolished surfaces ( Figure 3)
under identical loading and oil conditions. The DOE analysis
was conrmed by running two tests using 385 N (Hertzian
contact pressure of 2.72 GPa) and 80 L of oil. Figure 4 estab-
lishes clear evidence and conrms the DOE ndings related
to surface roughness and failure time.
Four replicates of polished cylinders and threes replicates
of unpolished cylinders were tested under a load of 385 N
and 50 L oil to check the consistency and the reproduc-
ibility of boundary lubrication. Number of cycles to failure,
Figure 3 | Desirability of the model under variation of loading (N) and
oil volume (L) for polished and unpolished surfaces.
Figure 4 | Friction variations of polished and unpolished test rings performed at 385 N loading under 80 L of boundary lubrication in com-
mercial oil.
Point 11: Eliminate management by objectives. Production targets encourage high output and low quality. 57
Figure 5 | Friction coefcients, wear proles, and wear volume vari- Figure 6 | Friction coefcients, wear proles, and wear volume vari-
ations of four polished test performed at 385 N loading under 50 L ations of three unpolished test performed at 385 N loading under 50
of boundary lubrication. L of boundary lubrication.
wear proles, and wear volumes in the polished cylinders Amount of Oil and Additive Concentration Effects on
were very consistent, with a variation of less than 10%, which Polished Tests
is signicant in tribology (Figure 5). However, the same re- The boundary lubrication tests were conducted with 4080
sponses were different and inconsistent in the unpolished L oil to examine the role of the amount of oil in the bound-
cylinders (Figure 6). The friction coefcient and wear vol- ary layer on the durability of the tribological lm formed. All
ume were clearly better in the conditions shown in Figure 5. the tests were conducted at a xed load of 385 N (Hertzian
The wear prole was measured using the prolometer at six contact pressure of 2.72 GPa). When a small amount of oil
locations 30 apart and were extremely reproducible. Know- was used, in oil-starved conditions occurred earlier in the
ing the diameter of the cylinder, the wear volume was easily test, as indicated in Figure 7, which presents the variation of
determined. The three outcomes measured from these tests friction coefcients and wear proles for the tests with 40,
(polished and unpolished) clearly indicate that the test is 50, 60, and 80 L oil as a function of number of cycles; the
viable and useful to examine the mechanism of boundary number of cycles to nal breakdown of the boundary layer is
lubrication. also shown. It is evident that the onset of abrasive wear rep-

Figure 7 | Polished test
rings performed at 385 N
loading under different
quantities of oil lubrica-
tion on surface boundary.
Friction coefcients and
wear prole representa-
tions of these tests for the
following oil volumes: (A)
40 L, (B) 50 L, (C) 60 L,
and (D) 80 L.
Figure 8 | Wear volume

and oil lm thickness as a
function of oil volume on
the boundary of the pol-
ished tests under extreme
load of 385 N.
resented by the increase in friction coefcient appeared rst to the tests with 80 L oil. The data in Figure 7 present two
in the 40 L test due to the inability to form a stable antiwear replicates of each test. It is immediately evident that the most
tribolm. When 60 and 80 L oil was used, a stable tribologi- severe conditions occur for tests that had insufcient ZDDP to
cal lm was formed, resulting in an increased time to break- develop a stable and continuous tribolm for wear protection.
down. When more than 80 L oil was used, the excess oil was Figure 8 shows the relationship between the thickness of the
spun off during the rst few cycles and results were similar oil layer on the cylinder (not contact lm thickness, which

Figure 9 | Polished test cyl-
inders performed under dif-
ferent loading conditions
using 50 L of oil lubrica-
tion on the surface bound-
ary. Polished test cylinders
performed under different
loading conditions using 50
L of oil lubrication on sur-
face boundary. Variations in
wear prole for Figure 6a
for the following loadings:
(A) 405 N, (B) 395 N, (C)
385 N, (D) 375 N, (E) 365 N,
(F) 356 N, (G) 336 N, (H)
307 N, (I) 317 N, and (J) 297
N.
was between 40 and 78 nm and was estimated from the equa- the importance of ZDDP (Mourhatch and Aswatch (27); Min-
tions referenced by Grubin (23), Dowson and Higginson (24); fray, et al. (33); Bancroft, et al. (34); Ferrari, et al. (35), (36);
Archard and Cowking (25); and Hamrock and Dowson (26)) Ramakumar, et al. (37); Unnikrishnan, et al. (38); Bancroft
and the wear volume at the end of the test. The thickness of and Park (39)). Data on polished and unpolished tests (Table
the oil layer was calculated from the width of the wear lm 2) under variant loading conditions were used in DOE to
observed in the tests and the amount of oil applied for each optimize amount of oil and loading conditions.
of the tests; because the width of the oil layer was essentially
the same in all cases, increasing the amount of oil resulted in Effect of Loading Pressure on Boundary Lubrication in
an increase in the thickness of the layer. There was an inverse Polished Tests
relationship between the amount of oil in the layer and the Ten tests were conducted at loads between 297 and 405 N
wear volume at the end of the test, indicating that the thick- (corresponding to a Hertzian contact pressure of 2.52.77
ness of the oil layer (i.e., amount of oil present and hence the GPa) using 50 L of boundary lubrication oil. Friction coef-
amount of ZDDP present) and not the lm thickness at the cient as a function of number of cycles was recorded and
point of contact was critical in determining the strength and the wear proles were measured. Figures 9a, 9b, and 10 pres-
durability of the protective tribolm formed on the surface of ent the friction, wear volumes, wear proles, and number of
the ring. This was conrmed by previous studies that analyzed cycles to failure variations as a function of loading conditions.
60 Point 12: Remove barriers to pride of workmanship. Treat workers the same. Dont make them compete with other workers for rewards.

Figure 10 | No. of revolutions to failure and wear volume vs. load under 50 L of boundary lubrication (polished tests).
These gures established that as the load decreased, the time

to failure as depicted by the steep rise in friction coefcient
increased and less frictional uctuation resulted. The 405 N
loading showed a severe rise in friction at the start of the test
and a short time for full breakdown. In contrast, the 297 N
loading showed no sign of failure and a steady-state coef-
cient of friction. These tests present a detailed description of
loading effects. The small inconsistency that exists was prob-
ably due to the insufcient variation of the load. The lower
steady-state friction coefcient tests exhibited the lowest wear
width, wear depth, and wear volumes as depicted in Figure 9b
(graphs F through J) and Figure 10. These wear proles are
a direct representation of the variation of friction coefcients
and total time to failure. The high and low wear depth and
wear volumes correlated with the high and low number of
cycles to failure. Wear volumes presented the direct correla-
tion between the loading condition and the wear material
loss. This is attributed to the wear mechanism explained by
the SEM and EDS images.
Figure 11a | SEM and EDS analysis for 297 N wear track under 50 L
SEM and EDS Analysis of Polished and of boundary lubrication (polished tests).
Unpolished Conditions
Four polished tests (297, 336, 385, and 405 N loads) that
represent extreme pressure loading were selected for SEM and the wear track is shown in Figures 11a and 11b for the 297
EDS to be analyzed and compared to two unpolished tests run and 336 N polished tests. These gures indicate the presence
under the same conditions. of more phosphorus than sulfur on the wear surfaces, indicat-
SEM micrographs of the surfaces obtained after testing ing the presence of a tribolm. The lm has been shown to oc-
provided evidence of adhesion, abrasion, and plastic deforma- cur at low and intermediate loads (Smith (20)). The severity
tion. Figure 11 shows secondary electron images of the wear of the wear debris and material transfer at the extreme loads
surfaces of the cylinders at the end of the selected polished of 385 and 405 N suggest that no lubrication lm protected
and unpolished tribological tests. A smooth surface with in- the metal surfaces and more metal-to-metal contact resulted
signicant wear and clear phosphorus concentration inside where extensive adhesive pullout was present, leading to both
62 Point 13: Implement education and self-improvement. Build skills to make your
Figure 11b | SEM and EDS analysis for 336 N wear track under 50 L Figure 11d | SEM and EDS analysis for 405 N wear track under 50 L
of boundary lubrication (polished tests). of boundary lubrication (polished tests).
DS analysis for 297 N wear track under 50 L of boundary lubrication (unpolished tests).
Figure 11c | SEM and EDS analysis for 385 N wear track under 50 L Figure 11e | SEM and EDS analysis for 297 N wear track under 50 L
of boundary lubrication (polished tests). of boundary lubrication (unpolished tests).
higher friction and wear as shown in the higher magnication by an FeS solid tribolm, which is more adherent and more
SEM images (Figure 11g). It appears that sulfur and phos- stable. The unpolished 297 N secondary electron image (Fig-
phorus exist on the wear scar but not centered in the wear ure 11e) shows a featureless wear track with less phosphorus
track. When the load reached 405 N, phosphorus concen- concentration inside when compared to the polished test.
tration diminished greatly in both polished and unpolished This indicates that the wear debris formed because the pull-
tests, but sulfur was still showing some signicance (Figures ing of asperities diminished the presence of tribolm under a
11d and 11f). Other studies (Smith and Bell (40)) have also starved lubricant volume of 50 L. Fuller, et al. (41) carried
indicated that at extreme pressures organic polyphosphate out a spectroscopy study using X-ray absorption near-edge
tribolms are unable to provide protection and are replaced spectroscopy (XANES) to identify sulfur and phosphorus-
workforce more adaptable to change and better able to identify and achieve improvements. 63
containing species. It was determined that in tribolms, long-
chain polyphosphates existed at lower temperature than in
thermal lms. They also found that increased heating times
caused increased lm thickness and increased levels of wear.
Willermet, et al. (42) used scanning force microscopy to in-
vestigate the wear resistance of antiwear lms generated under
conditions designed to simulate engine performance. Films
were produced under conditions of mild wear, expected to
lead primarily to phosphate formations, rather than under
extreme pressure conditions that may favor the growth of
suldes. Willermet, et al. (42), Fuller, et al. (43), and Kasrai,
et al. (44), (45) provided evidence through XANES and con-
tact voltage resistance that showed that steady-state friction
and moderate contact loading will lead to the formation of
antiwear tribolm that is capable of minimizing wear and
providing protection. These experiments indicate that bound-
ary tests give better performance when loading conditions and
Figure 11f | SEM and EDS analysis for 405 N wear track under 50 L oil amount are optimized with respect to surface roughness.
of boundary lubrication (unpolished tests).
Optimization
The interactions between the quantity of oil on surfaces and
loading conditions were directly proportional to the wear
performance. The signicant improvement was shown dur-
ing the optimization process using the DOE software. DOE
broad analysis showed the effectiveness of an antiwear lm
during different loading condition. Optimum performance
and desirability are shown in Figures 12a and 12b. Increasing
oil quantity and thus increasing ZDDP additives and decreas-
ing load is signicant for all tests. Surface roughness and oil
volume worked in the same direction in boundary lubrica-
tion when compared to loading conditions. Desirability was
optimized for the polished and unpolished testing conditions,
and a selected optimized oil volume of 62 L and load of 307
Figure 11g | Higher magnication SEM for 385 N and 405 N loadings Figure 12a | Optimized desirability of the model under optimized
under 50 L of boundary lubrication for the polished tests. loading (N) and oil quantity (L) for polished surfaces.

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N (Hertzian contact pressure of 2.53 GPa) were used to retest
the boundary lubrication regime for the stated conditions of
surface roughness. Important responses in the model such
as wear depth and number of cycles to failure were recorded
and calculated and then the cylinders were carefully prepared
for SEM and EDX analysis. Figure 13 presents the frictional
events, wear volumes, and wear depth for the optimized pol-
ished and unpolished experiments under the same optimized
oil and load conditions. The peak friction was established
earlier in the polished test when the breakdown of the tri-
bolm occurred. This rise in friction coefcient resulted in
a rise in temperature and the reestablishment of the protec-
tive antiwear lm followed by a plateau regime in which the
coefcient of friction remained unchanged. However, there
were more friction uctuations and some increases in the wear
depth and wear volume in the unpolished test. The duration
of these tests and the improved tribolms depended greatly on
the optimized load and the ZDDP additives in the oil volume.
The amount of wear occurring during the optimized condi-
Figure 12b | Optimized desirability of the model under optimized tions was minimal compared to the previous experiments. The
loading (N) and oil quantity (L) for unpolished surfaces. effects of phosphorus concentration and loading conditions
Figure 13 | Optimized polished and unpolished tests under optimized loading of 307 N and optimized oil volume of 62 L. A and B represent
friction coefcient, wear proles, and wear volumes for polished and unpolished tests, respectively.
66 Point 14: Make transformation everyones job. Analyze each small step and understand how it ts into the larger picture.
were established earlier by Mourhatch and Aswath (27). associated with the best wear performance. When both tracks
SEM micrographs in secondary electron mode of the wear are compared, the unpolished test shows a larger region of
tracks generated from these two tests are shown in Figure the wear track. The results presented by SEM were conrmed
14. It can be seen that the wear track is very smooth in both by the EDS analysis shown in Figures 15 and 16. The inten-
cases, indicating the presence of a stable tribolm, which is sity of phosphorus formation is higher when the polished
Figure 14 | SEM images for opti-

mized polished and unpolished
tests under optimized loading
of 307 N and optimized oil vol-
ume of 62 L. A and B represent
the polished and unpolished
tests, respectively.
Figure 15 | EDS using X-rays of

wear track for optimized pol-
ished and unpolished tests un-
der optimized loading of 307 N
and optimized oil volume of 62
L. A and B represent the pol-
ished and unpolished tests, re-
spectively.

Figure 16 | EDS images of phosphorus for optimized polished and unpolished tests under optimized loading of 307 N and optimized oil volume
of 62 L. A and B represent the polished and unpolished tests, respectively.
surfaces are compared to the unpolished surfaces, indicating In the current study, the solution provided led to the reduc-
the formation of the tribolms in both, with more stability tion of time-consuming experimentations and the optimiza-
in the case of polished conditions. The establishment of such tion of boundary lubrication for specic surface roughness.
a tribolm has been previously reported (Huq, et al. (45)). Optimum lower load favors stable tribolm formation and a
small amount of abrasive wear, whereas at higher extreme loads
CONCLUSION instability of the tribolm will dominate with respect to both
In this article, we presented a novel solution for an optimized surfaces considered. SEM micrographs in secondary electron
condition of boundary lubrication. The essence of the new mode and EDS analysis of wear tracks indicate that at higher
methodology is represented in several testing conditions that loads and starved lubrication regime the phosphorus concen-
yield the approximate solution of the boundary lubrication tration is reduced and wear debris can be observed in the wear
problem. This solution can be presented clearly in terms of tracks, whereas at the optimum loading condition darker and
wear, amount of ZDDP fully formulated oil, load, and SEM smoother surfaces covering the wear scars were conrmed.
analysis of selected testing conditions.
Wear under boundary lubrication is controlled by the nature ACKNOWLEDGEMENTS
and effectiveness of the tribolms formed on the surface. The The authors thank the reviewers for their useful suggestions
extent of wear under boundary lubrication is directly related and the Faculty of Engineering at the University of Balamand.
to the variation of friction coefcient during the test. Polished Support provided by the State of Texas as part of a Technology
and unpolished tests were conducted to examine the behavior Development and Transfer Grant and Platinum Research Or-
of the tribolms and to optimize the loading and volume of oil ganization LLC is gratefully acknowledged. The authors thank
containing ZDDP using DOE and to optimize the stable forma- Professor Pranesh B. Aswath, Professor Ronald L. Elsenbau-
tion of tribolms under these conditions. mer, and Dr. Harold Shaub for useful discussions.
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APPENDIX A
Figure A1 | Standardized effect of the wear depth response with Figure A2 | Standardized effect of the number of cycles to failure
respect to half-normal percentage of probability. response with respect to half-normal percentage of probability.
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TABLE A1
ANOVA for selected factorial model Analysis of variance table [Partial sum of squares - Type III]
Wear Depth (m)
Response 1
Source Sum of Squares df Mean Square F Value p-value Prob > F
Model 724.00 7 103.43 1264.40 < 0.0001 signicant

A-oit quantify 97.12 1 97.12 1187.30 <0.0001
B-surface rot 23.36 1 23.96 292.92 <0.0001
C-load 586.85 1 586.85 7174.21 <0.0001
AB 0.31 1 0.31 3.77 0.0333
AC 10.99 1 10.99 134.34 <0.0001
BC 2.06 1 2.06 25.17 0.0010
ABC 2.71 1 2.71 33.03 0.0004
Pure Error 0.65 8 0.082
Cor Total 724.65 15
The Model F-value of 1264.40 implies the model is signicant. There is only a 0.01% chance that a Model F-Value this large could occur due
to noise.
Values of Prob > F less than 0.0500 indicate model terms are signicant.
In this case A, B, C, AC, BC, ABC are signicant model terms.
Values greater than 0.1000 indicate the model terms are not signicant.
If there are many insignicant model terms (not counting those required to support hierarchy), model reduction may improve your model.
Std. Dev. 0.29 R-Squared 0.9991
Mean 10.81 Adj R-Squared 0.9933

C.V.% 2.64 Pred R-Square 0.9964
PRESS 2.62 Adeq Precision 92.292
The Pred R-Squared of 0.9964 is in reasonable agreement with the Adj R-Squared of 0.9933.
Adeq Precision measures the signal to noise ratio. A ratio greater than 4 is desirable. Your ratio of 92.292 indicates an adequate signal. This
model can be used to navigate the design space.
TABLE A2
ANOVA for selected factorial model Analysis of variance table [Partial sum of squares - Type III]
Number of Cycles to Failure
Response 2
Source Sum of Squares df Mean Square F Value p-value Proli > F
Model 2.148E+010 7 3.069E+009 5511.49 <0.0001 signicant

A-oil quantify 1.134E+089 1 1.134E+009 2036.37 <0.0001
B-suffsce rot 3.626E+008 1 3.626E+008 172B.49 <0.0001
C-load 1.830E+010 1 1.830E+010 32860.74 *0.0001
AB 2.747E+008 1 2.747E+008 433.34 <0.0001
AC 1.180E+008 1 1.183E+008 212.37 <0.0001
BC 2.764E+008 1 2. 764E+008 436.32 *0.0001
ABC 4.192E+008 1 4.192E+008 752.82 <0.0001
Pure Error 4.455E+006 8 S.569E+005
Cor Total 2.149E+010 15
The Model F-value of 5511.49 implies the model is signicant. There is only a 0.01% chance that a Model F-Value this large could occur due
to noise.
Values of Prob > F less than 0.0500 indicate model terms are signicant.
In this case A, B, C, AB, AC, BC, ABC are signicant model terms.
Values greater than 0.1000 indicate the model terms are not signicant.
If there are many insignicant model terms (not counting those required to support hierarchy), model reduction may improve your model.
Std. Dev. 746.24 R-Squared 0.9998
Mean 52393.75 Adj R-Squared 0.9996

C.V.% 1.42 Pred R-Square 0.9992
PRESS 1 .782E+007 Adeq Precision 170.087
The Pred R-Squared of 0.9992 is in reasonable agreement with the Adj R-Squared of 0.9996.
Adeq Precision measures the signal to noise ratio. A ratio greater than 4 is desirable. Your ratio of 170.087 indicates an adequate signal. This
model can be used to navigate the design space

Patented
AccuSense
technology for
unparalleled
accuracy
Integrated
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functionality
Anti-Wear,
Extreme Pressure,
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The Future
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www.ducom.com | info@ducom.com
New York (USA ), Groningen (Netherlands), Bangalore (India)
NEWSMAKERS
TOP STORIES The distribution partnership be- competition focused on solutions for
tween the two companies will cover reliability and resilience in the offshore
SEA-LAND CHEMICAL ANNOUNCES most of the U.S., along with all territo- helicopter industry. Spectro Scientic
PARTNERSHIP WITH LOCKHART ries within Canada and Mexico. presented its Q5800 Expeditionary Flu-
CHEMICAL Sea-Lands focus on the lubricant id Analysis System (EFAS), a 33-pound,
Westlake, Ohio-based, Sea-Land Chemi- and metalworking additives market battery-operated, man-portable lubri-
cal Co. announces it is now an autho- with their technically trained sellers cation analysis lab that provides com-
rized distributor for Lockhart Chemical makes them the perfect channel to mar- prehensive results in 10 minutes on a
Co. and its line of branded products ket to help us grow our business, says ight line or in a maintenance shop.
in North America. Under this agree- STLE-member Raj Minhas, president Spectro Scientic originally devel-
ment, Sea-Land will represent the EZ and CEO of Lockhart Chemical Co. It oped the Q5800 under contract with
Mulz, Counter Rust, Lubristay, is clear to us that they are very familiar the U.S. Military to analyze lubrication
Cuprisan and Coolsurf brands of with our product range and are ready oil and hydraulic uids for mainte-
additives and surface protection tech- to hit the ground running. nance and reliability improvements in
nologies to the lubricants market. aerospace, ground vehicles and auxil-
We are excited about the oppor- SPECTRO SCIENTIFIC WINS iary equipment. The Q5800 provides
tunity to represent Lockhart Chemical RELIABILITY AND RESILIENCE detection capability for early stage me-
Co. in North America, says STLE- INNOVATION COMPETITION chanical failure in oil-wetted systems.
member Joe Clayton, president of Sea- Chelmsford, Mass.-based, Spectro Sci- The system is typically operated by a
Land Chemical Co. Lockhart manu- entic announces a joint rst place line mechanic, delivering test results
facturers a full line of high-quality nish with Airbus Helicopters in a and maintenance recommendations in
additives, packages and surface protec- vote ranking contestants at the 2017 fewer than 10 minutes via a computer-
tion technologies for the lubricant in- HeliOffshore Conference and Annual ized expert system.
dustry. We look forward to the oppor- General Meeting in Budapest, Hungary, Our technology has successfully
tunity to offer these high-performance on May 14, 2017. improved reliability and reduced main-
products to our customers. This years Shark Tank Innovation tenance costs in military applications
74 When the U.S. could ignore his ideas no longer, Deming launched the Total Quality Management movement in corporate America.
over the past several years, says Bob
Wopperer, vice president of business
development for Spectro Scientific.
We are pleased to bring the benets
of this advanced technology to the
commercial aerospace market where it
can help improve reliability and safety
across the eet.
SONGWONS NEW PILOT PLANT

Ulsan, South Korea-based, SONGWON
Industrial Co., Ltd., announces its new
pilot plant in Panoli (Gujarat), India,
has come on stream, thereby strength-
ening the organizations overall special-
ty chemicals development capability.
Built on SONGWONs Indian site
with all the necessary main unit opera-
SONGWON plans to meet key industry needs with its new pilot plant. (Photo courtesy of
tions, the new plant is equipped with
SONGWON Industrial Co., Ltd.)
the most up-to-date technologies and
materials to produce a wide range of
chemicals for a broad spectrum of ap-
plicationsfrom one kilo up to several role in ensuring that SONGWON can Schaefflers New Work initiative.
hundred kilo samples. To reinforce the continue developing new industrial Maria-Elisabeth Schaefer-Thumann,
organizations position in existing ar- technologies to meet evolving market family shareholder, attended the open-
eas of business and enhance its ability needs and make it possible for us to ing ceremony together with Georg F.
to enter new areas, the new pilot plant reliably supply customers with innova- W. Schaefer, chairman of the Super-
will be supported by the SONGWONs tive products for testing and approval. visory Board, and Klaus Rosenfeld,
strong local R&D team in Panoli, as CEO of Schaefer. The globally active
well as its central Technology Innova- SCHAEFFLER EXPANDS automotive and industrial supplier has
tion Center located in Maeam, Korea. S.C. PLANT, PARTNERS WITH created over 100 new jobs at the Fort
Technology and product inno- AUDI ON POWERTRAINS Mill location.
vation is at the core of SONGWONs The Schaefer Group, based in Herzoge- Schaeffler has invested around
business strategy. With our high-qual- naurach, Germany, celebrates the ex- $36.5 million (approximately 32.5 mil-
ity manufacturing expertise and strong pansion of its Fort Mill plant in South lion euros) to expand the production
R&D, we have already earned a solid Carolina. capacities of one of its two Fort Mill
reputation in the industry, says Gia- At the same time, a new ofce build- plants. Moreover, a new, multi-func-
como Sasselli, leader operations. This ing was opened that has been adapted tional administration building has been
new facility will play an important to the new working environments of set up, as well as a new plant entrance
Deming was hired as a consultant by Ford, GM, Dow Chemical, Hughes Aircraft and others. Jack Welch implemented Demings strategies at GE. 75
tive markets, says Rosenfeld.
Expanding the plants production
space by around 3,250 square meters
has increased capacities in the areas of
stamping, heat treatment and mount-
ing of axial bearings. The new admin-
istration building offers around 6,000
square meters of space for modern
ofce work places and, in addition to
that, a multimedia conference center
and a company restaurant.
Also, Schaefer and Audi agreed on
an extensive cooperation in the devel-
opment of the powertrain for the next
three generations of the Formula E race
The expansion of Schaefers Fort Mill plant in South Carolina. From left: Jrgen
car. Schaefer chief technology ofcer
Thumann; Klaus Rosenfeld, CEO of Schaefer AG; Georg F. W. Schaefer, chairman of
professor Peter Gutzmer and Peter
the Supervisory Board; Henry McMaster, governor of South Carolina; Maria-Elisabeth
Schaefer-Thumann, deputy chairperson of the Supervisory Board; Dr. Peter Wittig, Mertens, member of the Board of Man-
ambassador of the Federal Republic of Germany to the U.S.; and Bruce Warmbold, CEO agement, Technical Development AUDI
Americas at Schaefer. (Photo courtesy of Schaefer.) AG, signed a three-year agreement in
Berlin-Tempelhof.
Schaefer has been involved in the
that has been adjusted to accommodate we are committed to further grow our innovative electric racing series from
the locations enlargement and increas- business in the Americas and to invest Day One and designing, developing
ing trafc. We want to deliver long- in the U.S. in capital and in the people and building the powertrain for the only
term value as a true partner. Therefore both in the industrial and the automo- German Formula E race car in the inter-
METALWORKING
ADDITIVES LIKE
YOUVE NEVER SEEN
Fulfilling orders nationally.
national eld in a highly committed and this joint effort and will continue the The acquisition of Groeneveld will
successful partnership with Team ABT. success story of ABT Schaefer Audi further expand our presence in the
The partnership will include joint work Sport, which is already an impressive automatic lubrication systems space,
on the electric motor, suspension and one, says Gutzmer. which we entered in 2013 with our
power electronics for the powertrain. acquisition of Interlube, says Richard
The basic concept for the next- TIMKEN TO ACQUIRE G. Kyle, Timken president and chief
generation powertrain of the Formula GROENEVELD GROUP executive officer. Groeneveld will
E race car has been nalized, and some North Canton, Ohio-based, The Tim- bring a strong brand and management
of its components are already being ken Co., a global leader in engineered team, a global customer base and an
tested. Behind the scenes, Schaefer bearings and mechanical power industry-leading product portfolio that
and Audi had worked together in For- transmission products, announces it has an attractive market position in off-
mula E in some areas. Now the ofcial has reached an agreement to acquire highway equipment and heavy trucks.
signing of the agreement elevates this Groeneveld Group, a leading provider of Groeneveld Group is headquartered
existing active partnership to a higher automatic lubrication solutions used in in Gorinchem, Netherlands, with man-
level with a long-term focus. We are on- and off-highway applications, for ufacturing facilities in Italy. Automatic
delighted to now have sealed for the approximately $280 million. lubrication delivery systems, which
next three years this increasingly closer For the 12 months ending May 31, enhance vehicle and machine uptime
partnership that we have been actively 2017, Groeneveld Group sales were ap- through automated maintenance and
engaged in with Audi in Formula E for proximately $105 million. The trans- safety support, represent the predomi-
quite some time. Just like we have been action is expected to be accretive to nance of the companys offering.
innovatively cooperating with Audi adjusted earnings per share in 2017. As part of the transaction, Henk
for many decades both in motorsport Additionally, Groeneveld Group has a Groeneveld, sole shareholder and
and, of course, in the development strong margin prole, which is expect- non-executive president, will be re-
and manufacturing of components for ed to be accretive to Timkens EBITDA tiring from the company. Henk led
production cars, I am sure that both margin and to be further enhanced as Groeneveld for four decades and made
partners are going to give their best to a result of synergies. it the company it is today, and he has
www.palmerholland.com | 800.635.4822

put in place a great leadership team, Award of Meritto Dr. Andy L. Pickard, and test methods within committee
says Kyle. We wish Henk and his fam- consultant in Qualicum Beach, British D02. He has been a member of ASTM
ily well in retirement. Columbia, Canada. The prestigious International since 1983 and has won
award, which includes the accompa- the Frank W. Reinhart Award (2015),
ASTM INTERNATIONAL COMMITTEE nying title of Fellow, is ASTMs highest the Eagle Award (2014), the Award of
PRESENTS TOP ANNUAL AWARD recognition for individual contribu- Excellence (2011-2013), the George
West Conshohocken, Pa.-based, ASTM tions to developing standards. V. Dyroff Award of Honorary Commit-
Internationals committee on Petroleum The committee is honoring Pickard tee D02 Membership (2009) and the
Products, Liquid Fuels, and Lubricants for his dedication and knowledge of Award of Appreciation (2006), all pre-
presents its top annual honorthe standard specications, classications sented by committee D02.
Previously Pickard was a senior
fuels specialist of Petro-Canada until
2003. Aside from ASTM, he is a mem-
ber of the Canadian Society for Chem-
istry, Association of the Chemical Pro-
fession of British Columbia and Society
of Automotive Engineers International.
INGEVITY NAMES IMCD

AS DISTRIBUTOR
North Charleston, S.C.-based, Ingevity
announces the selection of IMCD, N.V., as
the distributor for its portfolio of lubri-
cant products in Brazil. The agreement,
effective May 2017, includes the distri-
bution of Ingevitys Altapyne, Diacid
and AltaLUB product lines.
We want to continuously improve
our customers experiences, says Sha-
na McCabe, Ingevitys global business
manager, lubricants and metalworking
uid additives. We see this partner-
ship with IMCD as a way to broaden
our territory to better service our cus-
tomers in the lubricants market.
We are thrilled to start this part-
nership with Ingevity, says Mauricio
Lopes, managing director for IMCD
INCREASED EFFICIENCY ENERGIZED BY
Brazil. Through this partnership, we
will be able to increase our portfolio of
LANXESS delivers effective, economical biocides and fungicides for specialties and expand our lubricants
OGVCNYQTMKPIWKFURNWU6GEJPKECN5WRRQTV5GTXKEGUTGCF[VQJGNR[QW business in Brazil.
QRVKOK\GRTQFWEVNGXGNUHQT[QWTURGEKECRRNKECVKQP1WTPreventol, IMCD is a global leader in the sales,
Biochek and Veriguard products are registered, reliable and available marketing and distribution of specialty
KPUQNWVKQPFKURGTUKQPRGNNGVUQTCMGUwww.mpp.us.lanxess.com chemicals, food ingredients and a com-
prehensive range of excipients and ac-
tive pharmaceutical.
EXXONMOBIL CONTINUES WORK ON

ROTTERDAM REFINERY
Preventol CMK Preservative and Preventol CMK 40 are approved by the FDA, EPA and NSF (HX-1) as
Following ExxonMobils latest update
antimicrobial preservative for lubricants with incidental food contact. The approved use is up to 1% active on the successful heavy lift of the reac-
ingredient (p-chloro-m-cresol). PREVENTOL is a registered trademark of LANXESS Deutschland GmbH.
BIOCHEK and VERIGUARD are registered trademarks of LANXESS Corporation. tors and vacuum fractionation tower,
the pre-assembled racks (PARs) for the
new hydrocracker have been installed

ZSCHIMMER & SCHWARZ
at the Rotterdam renery. Manufactured in Spain, the PARs
were shipped by water to the Rotterdam renery during mid-
May this year.
Often referred to as the spine of the hydrocracker, to-
gether the PARs weigh roughly 2,200 tons. The heaviest PAR
weighed an impressive 500 tons and its installation marked
the completion of the heavy lift portion of the construction
campaign. Now that the onsite PARs have been installed, fur-
ther piping and instrumentation work can commence. How long will your
uid last?
Extend the life of your metalworking
uids with Synergex multifunctional
amine additives. This range of lower-
odor, lower-volatility products from
Eastman offers excellent buffering
and pH stability.
Learn more at
www.synergexamine.com
Construction of the ExxonMobil Rotterdam renery.
PROMOTIONS & TRANSITIONS
ACME-HARDESTY WELCOMES NEW TEAM MEMBERS

Blue Bell, Pa.-based, Acme-Hardesty, a division of Jacob Stern
& Sons and an industry leader in
oleochemicals and biobased specialty
ingredients, has hired two new team
members.
As inventory planning coordina-
tor, Erik Tkacs will assist in managing
relationships with third-party storage,
service and transportation providers
for bulk and packaged products. He
also will execute day-to-day inventory Erik Tkacs
management tasks to ensure the high-
est level of inventory accuracy, lowest
inventory carrying costs and high levels
of customer service.
Previously Tkacs worked as an area
manager in the receiving department at
one of Walmarts eCommerce Fulll-
ment Centers. He graduated from York
College of Pennsylvania in 2015 with
a bachelors degree in supply chain and
Deanna Mulicka
operations management.
As inside sales and marketing spe-
80 Demings teachings were the starting point for Six Sigma, a set of management techniques to greatly reduce the probability that an error or defect will occur.
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cialist, Deanna Mulicka will grow and manage customer rela- try in the center of Moscow, and after
tionships with a focus on the personal care and food markets. having established strategic customer
She also will handle sales force back-up coverage, lead man- contacts, Schaefer has continued to
agement and inside marketing activities. consistently implement the strategy to
Prior to joining Acme-Hardesty, Mulicka worked for three strengthen its position on the Russian
years at Brenntag Solutions Group in Bethlehem, Pa., where market and develop new market op-
she was an industry representative. In this role she developed portunities by appointing a CEO Russia.
new sales opportunities and identied market share using cus- We are delighted to welcome Mr.
tomer relationships, technical knowledge and CRM databases. Shakhov to Schaeffler and believe
that he will successfully represent the Maxim Shakhov
SCHAEFFLER APPOINTS CEO RUSSIA Schaefer Groups automotive and in-
Maxim Shakhov has assumed the position of CEO Russia for dustrial divisions as well as cross-regional topics in the coun-
the Schaefer Group, based in Herzogenaurach, Germany, and tries of the Eurasian Economic Union, says Lindner.
will be based in Moscow. In this function, he will report di-
rectly to Prof. Dr. Rainer Lindner, CEO of Central & Eastern PILOT CHEMICAL NAMES
Europe and Middle East & Africa. EHS MANAGER
Following a successful career at DuPont and Vaillant in Jason Denlinger has been named Pilot Chemical Co.s (based in
Germany and Russia, Shakhov took over as CEO at the Bi- Cincinnati, Ohio) new corporate environmental, health and
onovatic Group, a Russian start-up company that specializes safety (EHS) manager. He will oversee the development and
in biotechnology, in 2016. With an engineering degree, a implementation of health and safety programs and maintain
masters of business administration and many years of ex- Pilots commitment to reducing the en-
perience on the Russian and German markets, he meets all vironmental impact of its operations.
the requirements to further develop the Schaefer Group for Denlinger brings more than 20
the future in Russia. years of experience in managing EHS
After moving its ofces into the House of German Indus- programs and most recently served
as director of EHS at AGC Glass Co.
North America in Cincinnati. He
earned his bachelors degree in geol-
ogy from Wright State University in
Dayton, Ohio. Jason Denlinger
Turning Your
Ideas Into Reality
With a prowess for processing

feedstocks into high-quality
TLT T R I B O LO G Y &
LU B R I C AT I O N
T E C H N O LO G Y
specialty hydrocarbon products,

Calumet is your partner for
customized base stocks,
process oils, specialty oils, Want to be recognized in TLT?
solvents and waxes. TLT is interested in hearing from our readers. Let us know
whats happening in your company. If you have news about a
new employee or if someone in your company has been rec-
ognized with an award or any other interesting items, let us
know. Please send us your news releases and photos for pub-
lication in Newsmakers to TLT Magazine, Attn: Rachel Fowler,
www.clmt.com 840 Busse Highway, Park Ridge, IL 60068, rfowler@stle.org.
2017 Calumet Specialty Products Partners, L.P.

everyday
Other companies call their solutions New.
We call them Everyday.
For more than 60 years, we have manufactured chemicals and
lubricant components tailored to meet our customers exact
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SOUNDING BOARD
Can Stock Photo Inc. / AJT
Which lubricant component will be most

critical to meeting future challenges for
your main lubricant applications?
Base stock was the overwhelming choice additives. After base stocks, the broad
among those TLT readers responding to category of additives came next in the
this months survey. The primary reason, following order: antioxidants, viscosity
as most respondents noted, is that base modiers, antiwear, EP, friction modiers,
stock accounts for more than 50% of the corrosion inhibitors and, for those in the
nished lubricant and is critical to all of its metalworking industry, antimicrobials and
functions. Base stocks also are the focus of lubricity additives. Fifty-one percent of
ever-evolving environmental regulations. survey respondents anticipate replacing
Plus, as one reader said, Improving base their base oil in the near future to meet
stock reduces the need for so many OEM, API or other specications.
84 Deming was nally recognized for his contributions in the U.S. in 1987 when he received a special award, the National Medal of Technology, at the White House. The
Base stock because it improves the Lubricity additives to enhance Base stock. Viscosities are constantly
life of the lubricant. lubricity for the lower-viscosity, decreasing.
less-polar base stocks. There is a
Viscosity modier. demand to reduce internal friction, Its different in each industry.
and the base stocks are becoming However, we reach the performance
Base stock due to the increasing more rened and less polar. The limits of antioxidants more often
demand of lower-viscosity grade oil demand for lubricity additives will than other components. Improving
requirements driven mainly by fuel increase. antioxidant technologies will be an
efciency and environmental important challenge to meet.
regulations.
Base oils, because of stricter envi-
D you
Do ou foresee
f esee having
h ing to
Effective additives that also are ronmental requirements.
change/upgrade your
eco-friendly to meet the ever
lubric
lubricant
ca t base
bas
se stock in
i the
changing requirements of environ- Fluoro-silicone oils.
near future to meet new OEM,
mental regulation.
API or other specications?
Chlorine-free lubricant additives for
Base stockviscosity and solvency. difcult operations.
Yes 51%
51%
PAG high-temp and polar properties. No 22% Viscocity modier, because they will
dene the fuel economy.
I believe that oxidation controls will Maybe 27%
be paramount in the future due to Based on responses sent to 13,000 TLT readers. Base stocks are likely to be the most
our constant battle to extend oil important component. There is still
change intervals while still protect- uncertainty around the availability of
ing the equipment. certain base stocks, feedstock
Base stock. In gas engines there will constraints, gas-to-liquid technology,
Antioxidants. be a tendency to change from Group alternative sources and meeting
I to Group II in base stock to reach required specications.
PAGs. Their oxidation and thermal more hours in use.
stability with better friction coef- Antiwear. Smaller reservoirs and
cient, high VI and inability to form Base stock, but it is a difcult greater power through put.
varnish make it a no brainer. If the question to answer. All components
so-called Big Oil know-it-alls would work together in a good formulation. Base stocks and VII as they form
learn more about these products and foundation of lubricants. Additive
stop publishing complete untruths Viscosity modier. technology is becoming a critical ele-
about these lubricants, they might ment as base oil technology changes.
realize the fact that PAGs are pretty Antimicrobials, because they have a
amazing. These uids seem to offer signicant inuence on metalwork- Better base stocks. Improving base
superior all-around performance to ing uid longevity. stock reduces the need for so many
any other base stocks and offer many additives.
other advantages. With PAGs Synthetic base stocks.
available in oil soluble, oil insoluble Base stock. Because of the high VI
and water soluble, the potential is Base stock. levels and percent of saturates.
enormous. Dialectic strength for
water soluble and oil insoluble is the Lubricity additives. In metalworking Base stock because it forms more
only disadvantage. tool life, it is one of the key elements than 50% of the nished products.
for cost reduction.
Sulfur-phosphorus auto gear oil Base stock, antioxidant and antiwear
additive package. For industrial applications such as will be the most critical component
gears and bearings, additives in for the fuel economy requirement
Base stock based on the uptick in general as efciency becomes more impacted on the weight, size of
the use of synthetics in the automo- important and designs leave less power train and transmission system
tive industry. room for errors. to be smaller and heavy duty.
award was in recognition of his determined support of statistical methodology, his contributions to sampling theory and his advocacy of these methods to corporations. 8 5
Friction modier. It needs to Corrosion inhibitors will play an
provide reduced friction in a very Which synthetic base stock increasing part in our product line as
complex system of components and Group III, IV or Vis likely to more and more of our lubricants are
uids. Not a simple thing when meett your
you future
tu lubricant
l b cant used in harsh environments.
many of those components compete needs?
for the surface as well. Base stock improvements will play
Group III 4 %
47% the most critical role as I meet future
I think base stock is always the most Group IV 34%
34% challenges.
important, whether it is line ush,
Group I, Group II, Group III or any Group V 19% Base stocks. Prices need to decrease
variety of synthetic. You can custom- Based on responses sent to 13,000 TLT readers. in order for the high performance/
ize it to your equipments needs. A specialty segment to remain viable in
sealed-for-life bearing should have a this increasingly frugal market.
synthetic lubricant while a basic,
leaky, hydraulic cylinder will do ne (1.) Antioxidant for engine oil to Multifunctional polymeric additives.
with line ush. minimize engine oil oxidation and
deposit formation and (2.) friction Base stock due to where the supply
Extreme pressure additive that is modiers for transmission oils for is coming from. I see that Group I is
REACH compliant. anti-shudder and smooth shifts. on the decline; Group II and higher
is on the rise. The higher the quality
Base stock. The majority of every Base stock solubility. Antioxidants the more demand it will see in the
lubricant is base stock. It must be the are critical to prevent varnish-like overall trend. Additive technology is
optimum for the application. Addi- deposits. always changing and fast. There will
tives merely enhance the base stock. always be a more efcient additive in
Antioxidants to give the greases the future as tech allows us more
Additives in general. longer life. options. Base stock is the volume
and bulk and sets the standard for
Additives. The range of base oil/ Base stock. With the anticipated cost the quality lubricant. If anyone can
stocks are limited, but additives play increase, we want to have quality and produce a base stock in the greatest
a big role in varying the performance still be able to have a prot margin. volume synthetically, that is the
parameters of the nished product. keystone.
(1.) Base stock (less of it), (2.)
You do not need such rened viscosity modier (more extreme Viscosity modier.
products for current applications. viscosity requirements), (3.) anti-
Remember, the more rened the wear additives (increased design BHT because of its environmental
more expensive. dependence on reliability in bound- classication.
ary lubrication).
VI improver. Biocide/preservative to successfully
With increasing pressure and load replace formaldehyde donors.
High-performance additives. (hydraulics, engine, etc.), I believe
VII will need to be more and more Antioxidants: longer service drains,
Group II and III base stocks. shear stable. more severe service in both indus-
trial and transportation.
Oddly enough, Group I. It seems to Base stock max operating temperature.
be important to blend it in with EP additives such as chlorinated
Groups II and III for overall perfor- Viscosity modier. Compatibility parafns due to EPA regulations.
mance. Note: This is a users/ when mixing greases.
speciers perspective, not a sup- Group III and PAO, for endurance.
pliers perspective. Performance additives and friction-
reducing additives are likely to be A key to driving down cost is base
Base stock since it is the major most important in meeting efcien- stock selection. I see a bigger drive
component and all other compo- cy requirements and power dense to Group II+ and Group III+ to
nents must be compatible with it. applications. replace PAO.


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The base oil is the base of the By far base stock selection. So many We predominantly make metalwork-
lubricant. The more properties we applications are depending on the ing uids, not lubricants. Having
can improve in the base oil, the oils ability to stay in grade in said that, the base stock is most
fewer additives we need, or we can adverse operating conditions. This is important because if the incorrect
stretch the application further. particularly true in automotive base stock is selected, additive
engine applications. solubility issues can result.
Friction modiers. With the expected
reduction in the use of zinc, phos- Base stock is a critical function that EP additives. Restrictions on
phorus and other metals, especially in needs to be met in our applications. chlorine and phosphorus are
PCMO, friction modiers will need to Our company has seen problems looming and processes are getting
be developed to replace them. with base stock that is too dark in more demanding.
color or has been re-rened and
In my companys case, it will be the contains an odor that is not pleasing Additive components.
urea grease thickener, which can to the end-user.
replace lithium soap and lithium Friction modiers in low-viscosity
complex thickeners that are rising in Detergent/dispersants because of engine oils (for large engines).
cost due to the demand for lithium high soot contamination in new
outpacing its supply. engines. Pressure-viscosity modiers.
Editors Note: Sounding Board is based on an email survey of 13,000 TLT readers. Views expressed are those of the respondents and do not reect the opinions
of the Society of Tribologists and Lubrication Engineers. STLE does not vouch for the technical accuracy of opinions expressed in Sounding Board, nor does inclu-
sion of a comment represent an endorsement of the technology by STLE.

CALL FOR PRESENTATIONS
73rd STLE Annual Meeting & Exhibition
May 20-24, 2018
Minneapolis Convention Center
Minneapolis, Minnesota (USA)
STLEs Annual Meeting & Exhibition is the industrys most respected

venue for technical information, professional development and
international networking opportunities. Each year STLEs conference
showcases some 500 technical presentations, application-based
case studies, best practice reports and discussion panels on technical
or market trends.
Education courses support professional development and prepare

qualied individuals for STLEs three certication programs: Certied
Lubrication Specialist, Oil Monitoring Analyst (I&II) and Certied
Metalworking Fluids Specialist. Our annual trade show and popular
Commercial Marketing Forum spotlight the latest products and
services of interest to lubrication professionals. STLEs conference is
a truly international event, with some 1,600 professionals from
around the world attending.
2018 presentations are being sought in the following areas:
Biotribology Nanotribology
Condition Monitoring Nonferrous Metals
Engine & Drivetrain Power Generation
Environmentally Friendly Fluids Rolling Element Bearings
Fluid Film Bearings Seals
Gears Surface Engineering
Grease Synthetic and Hydraulic
Lubrication Fundamentals Lubricants
Materials Tribology (includes Tribotesting
Ceramics and Composites) Wear
Metalworking Fluids Wind Turbine Tribology
Abstract Submission
If you are interested in presenting at STLEs 2018 Annual Meeting
& Exhibition, submit a 100-150-word abstract at www.stle.org.
Abstracts are due Oct. 1, 2017. Notication of acceptance will be sent
in December 2017. While you do not need to prepare a full manuscript
to be included on the meeting technical program, you are invited
and encouraged to submit a manuscript for review and possible
publication in STLEs peer-reviewed journal, Tribology Transactions.
For more information, please contact:

Merle Hedland mhedland@stle.org 630-428-3400
Follow us on #STLE2018
Society of Tribologists and Lubrication Engineers, 840 Busse Highway, Park Ridge, IL 60068, info@stle.org, www.stle.org.
TLT ADVERTISERS INDEX
AUGUST 2017 VOL. 73, NO. 8
Company Page
Acme-Hardesty Co. 19
BASF OBC
Calumet Specialty Products Partners, L.P. 82
Cannon Instrument Co. 26
Colonial Chemical 70
Want to Dover Chemical Corp.

Ducom Instruments
27
73
Heighten
Eastman Chemical Co. 80
El Corp. 83
Emery Oleochemicals 31
Your Evonik Oil Additives

Fluid Line Products
61
75
Industry F&L Asia Ltd.

Huntsman Petrochemical Corp.
IBC
65
Prole? Ingevity
Invista
J.A.M. Distributing Co.
IFC
3
30
Kao Chemicals 25
Can Stock Photo Inc. / Enjoylife
King Industries, Inc. 21

Include TLT in your Koehler Instrument Co., Inc. 81
marketing strategy. LANXESS Corp. 71, 78

Lexolube Div. Zschimmer & Schwarz 79
Your ad message Napoleon Engineering Services (NES) 88
will reach 13,000 Palmer Holland, Inc. 76, 77
PerkinElmer 49
lubricant-industry
Pilot Chemical 74
decision makers in its PolyOne Corp. 35
print and digital editions. Royal Manufacturing 95
Sasol North America 87
For information on how to customize Shanghai Starry Chemical Co. 9
a multimedia marketing program that Soltex, Inc. 39
ts your budget, contact:
STLE 2018 Call for Papers 89
National Sales Manager STLE Membership 93
Tracy Nicholas VanEe STLE 2018 Tribology Frontiers Conference 91
(630) 922-3459 The Elco Corp. 36
tnicholas@stle.org
United Color Manufacturing 7
Vanderbilt Chemicals, LLC 43
90 Deming continued to teach his business philosophy until his death in 1993.
Mark Your Calendar!
And learn about the technical,

2018 STLE environmental and social issues that
Tribology will most impact tribology research
in the 21st Century.
Frontiers For the fourth year STLE is convening an
Conference international community to share tribologys
most cutting-edge research. Come join us for
four information-packed days with tribologys top
mindsyoull leave with a better understanding
of how your companys products will fit into an
The Drake Hotel Chicago ever-evolving technical future.
Oct. 28-31, 2018 Visit www.stle.org for program updates,
online registration and hotel reservations.
TFC registration opens following
the 73rd STLE Annual Meeting &
Exhibition, May 20-24, 2018, in
Minneapolis.
See you in Chicago!
Cutting-edge tribology research
Networking
Industry recognition
Leadership opportunities
Invited speakers
International community
Idea sharing
Co-sponsored by ASME Tribology Division.
Can Stock Photo / malajski
Places of Interest The Art Institute of Chicago Museum of Science and Industry Follow us on:
Field Museum Shedd Aquarium Willis Tower Lincoln Park Zoo
John Hancock Building Navy Pier Millennium Park Michigan Avenue shopping
Society of Tribologists and Lubrication Engineers, 840 Busse Highway, Park Ridge, IL 60068 info@stle.org www.stle.org 847-825-5536
RESOURCES
TECHNICAL BOOKS
AN INTRODUCTION TO POLYSACCHARIDE ENVIRONMENTAL CHEMISTRY: AN ANALYTICAL

BIOTECHNOLOGY, SECOND EDITION APPROACH
Authors: Stephen E. Harding, Michael P. Tombs, Gary G. Author: Kenneth S. Overway
Adams, Berit Smestad Paulsen, Kari Tvete Inngjerdingen Publisher: Wiley
and Hilde Barsett Environmental Chemistry: An
Publisher: CRC Press Analytical Approach covers the
Polysaccharides and related high essentials of environmental
molecular weight glycans are chemistry and focuses on mea-
hugely diverse with wide applica- surements that can be made in a
tion in biotechnology and great typical undergraduate laboratory.
opportunities for further exploita- It provides a review of general
tion. An Introduction to Polysac- chemistry nestled in the story of
charide Biotechnologya second the Big Bang and the formation of
edition of the popular original text the Earth and includes a primer
by Tombs and Hardingintroduc- on measurement statistics and
es students, researchers, clinicians quantitative methods to equip
and industrialists to the properties students to make measurements in lab. This book encapsu-
of some of the key materials in- lates environmental chemistry in three chapters on the atmo-
volved, how these are applied, some of the economic factors sphere, lithosphere and hydrosphere. It also describes many
concerning their production and how they are characterized instruments and methods used to make common environ-
for regulatory purposes. Available at www.crcpress.com. List mental measurements. Available at www.wiley.com. List Price:
Price: $129.95 (USD), hardcover. $79.95 (USD), hardcover.
STLE CERTIFICATION EXAMS

STLE LOCAL SECTION
MEETING CALENDAR
STLE is offering a certication exam in August. Here is the information on the exam:
Events listed here are local section
programs. For further details and a full August 24 from 8:30-11:30 a.m. at Lubrication Engineers Inc., 1919 Tulsa St. E,
listing of other upcoming section events Wichita, Kans.
in your area, visit www.stle.org.
Meeting announcements can be sent For the online registration form, go to www.stle.org; click on the professional devel-
to TLT Magazine, Attn: Rachel Fowler, opment tab at the top. Then go to certication, then registration. Online registration
rfowler@stle.org. closes two weeks prior to the exam date. Onsite registration may be available on a
rst come, rst serve basis. For more information and for other methods of register-
ing, you may contact STLE headquarters by emailing certication@stle.org or calling
AUGUST 2017
(847) 825-5536.
STLE Cleveland Section Golf
Outing, August 14, 10:30 a.m.
to 7 p.m. The format will WORLD TRIBOLOGY CONGRESS
be a four-person scramble.
Schedule includes a putting The Sixth World Tribology Congress (WTC 2017) is in Beijing, China, on Sept. 17-22,
content, cookout lunch, 2017. WTC 2017 aims to highlight recent important progress in all aspects of tribol-
modied shotgun start and ogy and strengthen the links between academia and industry.
dinner. Shale Creed Golf Beijing is the capital of the Peoples Republic of China and the political, cultural
Club, 5420 Wolff Rd., Me- and educational center. It is a modernized historic city, now endowed with world-
dina, Ohio. Contact: Buck class convention centers, advanced facilities and beautiful hotels and resorts.
Evans at buck.evans@sealand- WTC 2017 is organized by the Chinese Tribology Institute (CTI). It is expected
chem.com or Tyler Kuchta at that more than 800 oral presentations including plenary, keynote and invited talks,
Tyler.Kuchta@Lubrizol.com. will be given in nine technical tracks. Around 200 poster presentations also are
expected. For more information, visit www.wtc2017.org/en.

You work in a
technical world.
Should you belong to
a technical society?
Keeping current with technical changes in the lubricants
eld is a daunting task.
More than 3,000 of your peers have solved this problem by
joining the Society of Tribologists and Lubrication Engineers.
STLE is the premier technical organization representing lubrication
professionals and tribology researchers. Professionals from
industry, academia and government join STLE because they know
no organization offers a more complete look at the eld of tribology.
STLE provides the lubricant industrys highest level of technical
training and professional development. But the benets of membership
dont stop there.
STLE membership is a mark of distinction. It confers the seal
of authority on you and your organization and afliates
you with the worlds leading experts in lubrication.
You work in a technical world. You belong
in a technical society. You belong in STLE.
Learn more about the benets of
STLE membership and how to join at
www.stle.org.
Can Stock Photo Inc. / yellowcrest
Follow us on
Society of Tribologists and Lubrication Engineers, 840 Busse Highway, Park Ridge, IL 60068 847-825-5536 info@stle.org www.stle.org
CUTTING EDGE
Drs. Wilfred T. Tysoe &
Nicholas D. Spencer
Zeroing in on ZDDP tribolm growth

Models for the stress-activated growth of tribolms from ZDDP
were modied to include wear.
TWO RECENT CUTTING EDGE ARTICLES re- with graduate student Aydar Akchurin of the
ported on work that showed the growth rates University of Twente in the Netherlands, de-
of tribolms from ZDDP were accelerated by veloped a model in which the growth kinetics
contact stress1 or interfacial shear2 under con- were described by the Bell model but also in-
ditions in which the temperature rise caused corporated wear. Previous measurements had
by rubbing was negligible. In both cases, the shown that the hardness of ZDDP tribolms
lm growth rate was found to increase with decreased almost linearly with lm thickness,
contact pressure,1 or shear stress,2 in accor- so a simple wear model was adopted in which
dance with a model for force-activated chemi- the wear rate was taken to be proportional
cal reactivity rst described nearly 40 year to the lm thickness, with the proportion-
ago to understand cell adhesion,3 commonly ality constant being taken as an adjustable
known as the Bell model. This predicts that parameter. All of this information was inte-
the reaction rate should increase exponen- grated into a simulation program, which is
Figure 1 | Simulation and experimental
tially with shear stress, with a rate of increase freely available.4
data for tribolm formation from ZDDP
being dependent on a constant known as the They rst used their model to t the data
at a 600 nN load measured in an AFM.
activation volume. (Published with permission from Ref. [4].) without including wear, by adjusting the val-
The experimental results for the growth ues of the reaction activation energy and the
of tribofilms from ZDDP showed such an activation volume, and were able to reproduce
exponential increase but only up to some the initial lm growth rates. Wear was then
maximum growth rate, at which point growth question as to whether wear also occurred included and the simulation yielded very good
ceased! It was suggested that this was the re- during earlier stages of lm growth to inu- agreement with the growth kinetics measured
sult of an increase in the wear rate that then ence the results at lower stress. after the completion of an initial induction pe-
balanced the growth rate, but this raises the To address this issue, Dr. Rob Bosman, riod (see Figure 1).
Figure 2 | (a) Comparison of simulation and experimental data [5]. (b) Evolution of the wear rate with temperature. (Published with permis-
sion from Ref [4].)

Bosman and Akchurin then used their growth rate, to provide a self-limiting lm
model to study ZDDP lm growth in a mac- thickness. Importantly the values of reaction
roscale steel-on-steel contact using recently activation energy (between 65 and 75 kJ/mol),
published data from the University of Leeds.5 activation volume (30 to 85 3) and the con-
They used the experimental parameters from stant in the wear equation (3 to 7x10-4) were
that work by again tting the activation ener- essentially the same for both nanoscale and
gy, activation volume and the proportionality macroscale contacts.
constant in the wear formula. The results are As the authors point out, the values of
displayed in Figure 2a, where there is again reaction activation energy and activation
excellent agreement between the simulations volume are likely to depend on the nature Eddy Tysoe (left) is a distinguished professor of
and experiment. Here, the simulations also of the ZDDP. This simple analysis, and the physical chemistry at the University of Wisconsin-
were able to accurately reproduce the growth free availability of the code, will allow the Milwaukee. You can reach him at wtt@uwm.edu.
kinetics for different uid temperatures. model to be applied to measurements of the
Nic Spencer (right) is professor of surface science
Figure 2b shows the corresponding wear growth of lms from a variety of additives and technology at the ETH Zurich, Switzerland, and
rates, which increase as the lm becomes to further understand the physical origins editor-in-chief of STLE-afliated Tribology Letters
thicker, eventually becoming equal to the of these parameters. journal. You can reach him at nspencer@ethz.ch.
FURTHER READING
1. Tysoe, W.T. and Spencer, N.D. (2015), Reaction to rubbing, TLT, 71 (8), pp. 84-86.
2. Tysoe, W.T. and Spencer, N.D. (2016), The shear truth about ZDDP, TLT, 72 (10), pp. 102-104.
3. Bell, G.I. (2017), Models for the specic adhesion of cells to cells, Science, 200, pp. 618-627.
4. Akchurin, A. and Bosman, R. (2017), A deterministic stress-activated model for tribo-lm growth and wear simulation, Tribology Letters, 65, p. 59.
5. Ghanbarzadeh, A., Parsaeian, P., Morina, A., Wilson, M.C.T., van Eijk, M.C.P., Nedelcu, I., Dowson, D. and Neville, A. (2015), A semi-deterministic wear model
considering the effect of zinc dialkyl dithiophosphate tribolm, Tribology Letters, 61, pp. 1-15.
WEVE GOT A GREASE FOR THAT
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AUTOMOTIVE TRIBOLOGY
Dr. Edward P. Becker
The future of ying is near

Materials engineering and tribology are two big factors
when considering ying cars.
FLYING CARS ARE BACK IN THE NEWS. Aero-

Mobil1 is exhibiting a production model and
claims it will soon begin taking pre-orders for
the vehicle. Before you place a deposit,
though, consider a couple of other recent
statements from AeroMobil:
The vehicle is expected to go into full pro-
duction in the upcoming years with the rst
deliveries being made to customers by 2020
and The production of AeroMobils rst vehicle
will be limited to a maximum of 500 units and
is priced between 1.2 million1.5 million Euro
depending on nal customer specications.
Now consider some performance speci-
fications for the AeroMobil: top ground Materials and tribology are among the biggest challenges in achieving an acceptable
speed of 99.4 mph (160 kph), cruising air power-to-weight ratio in a ying car.
speed of 161 mph (259 kph), maximum aero
range of 466 miles (750 km), carrying capac-
ity of two passengers and maximum useable tions. However, the AeroMobil does not appear
load of 529 pounds (240 kg). While those to incorporate a large battery pack, probably REFERENCES
numbers might be acceptable to most cus- because of weight restrictions. The engine 1. From www.aeromobil.com.
tomers for a small car or a small propeller- directly powers a generator that provides 2. U.S. Environmental Protection
driven aircraft, some would note that one electricity to the wheel motors. Agency Report EPA-
can purchase both a higher-performance car One measure of specic output of an 420-R-16-010, Light Duty
and aircraft for less money. internal combustion engine is the power-to- Automotive Technology, Carbon
To be fair, a practical ying car is quite an displacement ratio. In 2015 the average au- Dioxide Emissions, and Fuel
engineering feat. Two major players in achiev- tomobile engine in the U.S. produced 64.1 Economy Trends: 1975-2016,
November, 2016.
ing an acceptable power-to-weight ratio are kW/l.2 The AeroMobil engine produces 112
materials engineering and tribology. Light- kW/l, nearly twice the specic output of the 3. Kenneth Holmberg, K., Andersson,
weight, high-strength materials for vehicle typical automobile. P. and Erdemir, A. (2012),
structures are necessary to maximize pay- Turbocharging provides the additional Global energy consumption due
to friction in passenger cars,
load. Carbon ber composites are used exten- oxygen to the cylinders to burn sufcient
Tribology International, 47, pp.
sively for body and interior assemblies. High gasoline to generate such high power, but
221-234. DOI: 10.1016/j.
strength-to-weight ratio metal alloys (alumi- also important are the use of wear-resistant,
triboint.2011.11.022.
num, magnesium and titanium) are used for low-friction materials in the engine compo-
critically stressed components in the suspen- nents and the use of advanced, low-friction
sion and powertrain where possible. lubricants in the engine and transmission.
The power plant for the AeroMobil is a Even today, as much as 13% of fuel burned Ed Becker is an STLE Fellow and
conventional two liter, turbocharged four- goes to overcome mechanical friction in the past president. He is president
cylinder, horizontally opposed, internal com- engine, with the piston and piston rings to the of Friction & Wear Solutions,
bustion engine paired with twin electric front- cylinder bore interface contributing over 50% LLC in Brighton, Mich., and
wheel motors. This hybrid conguration is of that amount.3 There is still plenty of op- can be reached through his
increasingly popular in automotive applica- portunity for the engine tribologist! website at www.frictionandwearsolutions.com.
96 Deming once said: 3% of the problems have gures. 97% of the problems do not.
F+L WEEK IS COMING TO MACAO...
6 - 9 M A R C H , 2 0 1 8
JOIN US FOR THE 24TH ANNUAL FUEL AND LUBRICANT INDUSTRY CONFERENCE
AND AWARDS, MACAO AT COTAI STRIP. START PLANNING NOW!
Get ready for F+L Week 2018, the premier fuel, lubricant, additive and base oils conference
in the Asia-Pacific region. Gain unparalleled access to industry thought leaders and decision
makers, and point your business in the right direction for growth.
Abstract submissions on all topics for conference presentation are now open.
THOUGHT LEADERSHIP. INDUSTRY AWARDS.

TABLE TOP EXHIBITION. NETWORKING.
T H E M E : S U S T A I N A B I L I T Y A N D U N C E R T A I N T Y
48 Fuels & Lubes International Quarter Two 2017
We create
chemistry
that makes
lubricant
formulators love
ester and PAG
base stocks.
Ester and PAG base stocks are used as co-solvents or main

fluids in lubricant formulations. Top performance criteria as
energy efficiency, longer drain intervals and improved equip-
ment protection will be achieved. When formulators meet
these performance criteria and take advantage of BASFs
best-in-class technology and manufacturing strengths, its
because at BASF we create chemistry. If you are interested in
our products please contact us: Basestocks.NA@basf.com
www.basf.com/lubes

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What is Diacid 1550 used for?

What is Diacid 1550 used for?

What are some features of plane bearings discussed in the article?

What are some features of plane bearings discussed in the article?

SYSTEMS, STRATEGIES & RESEARCH FOR LUBRICATION PROFESSIONALS AN PUBLICATION | AUGUST 2017

What can it do?

+ 3D Printing: The next

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+ New economic models drive

+ Selecting the right plane bearing

Digital TLT: Sponsored this month by Acme-Hardesty and Temix at www.stle.org.

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W W W. ST L E .O RG T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY AUGUST 2017 1

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W W W. ST L E .O RG T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY AUGUST 2017 15

Lubricant growth in Latin

KEY CONCEPTS New economic models are

16 AUGUST 2017 T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY W W W. ST L E .O RG

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W W W. ST L E .O RG T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY AUGUST 2017 17

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Stapels: My path to working in metalworking was somewhat

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Stapels: As a strategic decision, our lab