Do Nano-Additives Always Improve Electrified Lubrication? Insights from hBN-Containing Grease in Rolling Bearings Under Electrified Conditions
Abstract
1. Introduction
2. Materials and Methods
2.1. Materials
2.2. Preparation of the Grease Samples
2.3. Determining the Bearing Failures Using a Roller Bearing Test Rig Under an Alternating Current
2.4. Surface Characterization of the Bearing Raceways to Determine the Wear Patterns
2.5. Hardness Measurement of the Bearing Raceways
2.6. Analysis of Greases to Determine Their Degradation
3. Results and Discussion
3.1. Performance of the Greases Under Electric Current
3.2. Statistical Analysis of the Experimental Results
3.3. Determining the Degradation of Grease During the Tribo-Test
3.4. Analyzing Surface Damage of Bearing Raceways During Tribo-Testing
3.5. Limitations of hBN as a Nano-Additive Under Electrified Conditions
4. Conclusions
- The choice of lubricant is critical to protect bearings from failure due to the passage of electric current. In this work, the base grease performed significantly better than the commercial grease and hBN grease.
- The results indicate that during the tribo-test under electrified conditions, the base grease without any additives maintained a more stable lubricating film compared to the commercial grease and optimized hBN grease.
- The vibrations of the bearing with base grease (238.2 ± 27.83 mV) were approximately 7% less than the vibrations recorded during the test with commercial grease (337.79 ± 1.27 mV), indicating a more stable lubricating film was formed by the base grease.
- The addition of hBN nanoparticles did not yield the expected improvement in tribological performance under electrified conditions. The inferior performance of hBN grease is attributed to nanoparticle agglomeration; poor dispersion stability under combined mechanical, thermal, and electrical stresses; and charge accumulation due to the insulating nature of hBN, which led to sporadic high-energy electrical discharge events rather than continuous current dissipation. The vibrations generated in the bearings under electrified conditions using the hBN grease (optimized) (349.4 ± 16.7 mV) were 31% higher than those using the base grease (238.2 ± 27.83 mV).
- The formation of white etching areas (WEAs), micro-pitting, weld spots, plastic deformations, and fluting marks were identified as the primary failure mechanisms from the optical microscopic images.
- The difference ATR-FTIR spectra revealed that the base grease underwent the least chemical alteration under both electrified and non-electrified conditions, indicating its superior chemical stability. In contrast, the commercial grease and hBN grease exhibited larger absorbance variations, suggesting greater susceptibility to tribologically and electrically induced chemical changes.
- The iron content in the grease after the tribo-test was significantly higher in the commercial grease and hBN grease compared to the base grease, confirming that substantial wear debris was generated from the bearing surfaces lubricated with the commercial grease and hBN grease. This wear debris further contaminated the lubricant and accelerated the degradation process through a self-perpetuating cycle of wear and contamination.
Supplementary Materials
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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| Parameters | Unit | Value |
|---|---|---|
| Viscosity at 40 °C | cSt | 584.2 |
| Viscosity at 80 °C | cSt | 21 |
| Flash Point | °C | 250 |
| Fire Point | °C | 280 |
| Total Acid Number (TAN) | MgKOH/g | 0.62 |
| Sulfur Content | ppm | 5076 |
| Test Parameter | Unit | CG | BG | 0.1 wt.% hBN Grease | 0.5 wt.% hBN Grease | 1.0 wt.% hBN Grease |
|---|---|---|---|---|---|---|
| Unworked Penetration | mm | 272 ± 3 | 340 ± 3 | 334 ± 2 | 336 ± 2 | 336 ± 3 |
| Worked Penetration, 60 Double Strokes | mm | 266 ± 2 | 355 ± 2 | 329 ± 3 | 329 ± 3 | 330 ± 2 |
| Drop Point | °C | 180 ± 2 | 70 ± 2 | 80 ± 2 | 82 ± 2 | 82 ± 2 |
| Elements | Unit | CG | BG | 0.1 wt% hBN Grease | 0.5 wt% hBN Grease | 1.0 wt% hBN Grease |
|---|---|---|---|---|---|---|
| Boron | ppm | 40 | 12 | 5881 | 12,220 | 19,986 |
| Magnesium | ppm | 33 | 7 | 9 | 11 | 9 |
| Zinc | ppm | 156 | 106 | 128 | 131 | 131 |
| Phosphorus | ppm | 334 | 357 | 210 | 214 | 211 |
| Calcium | ppm | 501 | 137 | 139 | 148 | 152 |
| Molybdenum | ppm | 5 | 6 | 8 | 8 | 8 |
| Sulfur | ppm | 4975 | 5116 | 8611 | 8591 | 8626 |
| Lithium | ppm | 3224 | 1422 | 1329 | 1239 | 1291 |
| Experiment | Current (A) | Load (N) | hBN (wt%) |
|---|---|---|---|
| E1 | 6 | 100 | 0.1 |
| E2 | 6 | 200 | 0.5 |
| E3 | 6 | 300 | 1 |
| E4 | 8 | 100 | 0.5 |
| E5 | 8 | 200 | 1 |
| E6 | 8 | 300 | 0.1 |
| E7 | 10 | 100 | 1 |
| E8 | 10 | 200 | 0.1 |
| E9 | 10 | 300 | 0.5 |
| Bearing Parts | Carbon (%wt.) | Manganese (%wt.) | Silicon (%wt.) | Sulfur (%wt.) | Phosphorus (%wt.) | Chromium (%wt.) |
|---|---|---|---|---|---|---|
| Raceway | 0.934 | 0.381 | 0.234 | 0.011 | 0.005 | 1.421 |
| Bearing balls | 0.916 | 0.350 | 0.240 | 0.017 | 0.022 | 1.370 |
| Cage | 0.064 | 0.233 | - | 0.014 | 0.017 | - |
| Parameters | Degree of Freedom | Adjusted Sum of Squares | Adjusted Mean of Squares | F-Value | p-Value | % Contribution |
|---|---|---|---|---|---|---|
| Current | 2 | 11,071 | 5535.7 | 8.32 | 0.107 | 22.1 |
| Load | 2 | 25,816 | 12,908.1 | 19.39 | 0.049 | 51.5 |
| % hBN | 2 | 11,860 | 5930.2 | 8.91 | 0.101 | 23.6 |
| Error | 2 | 1331 | 665.5 | 2.8 | ||
| Total | 8 | 50,079 | 100 | |||
| Model Summary | S | |||||
| 25.7981 | 97.34% | 89.37% | 46.18% |
| Passage of Current | Grease | Unit | Fe Content |
|---|---|---|---|
| No current | Base grease | ppm | 219 |
| No current | Commercial grease | ppm | 226 |
| No current | hBN grease | ppm | 233 |
| With current | Base grease | ppm | 231 |
| With current | Commercial grease | ppm | 539 |
| With current | hBN grease | ppm | 556 |
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Bhaumik, S.; Reddy, B.L.M.; Paleu, V.; Chong, W.W.F. Do Nano-Additives Always Improve Electrified Lubrication? Insights from hBN-Containing Grease in Rolling Bearings Under Electrified Conditions. Technologies 2026, 14, 389. https://doi.org/10.3390/technologies14070389
Bhaumik S, Reddy BLM, Paleu V, Chong WWF. Do Nano-Additives Always Improve Electrified Lubrication? Insights from hBN-Containing Grease in Rolling Bearings Under Electrified Conditions. Technologies. 2026; 14(7):389. https://doi.org/10.3390/technologies14070389
Chicago/Turabian StyleBhaumik, Shubrajit, Byreddy Lakshmi Manohar Reddy, Viorel Paleu, and William Woei Fong Chong. 2026. "Do Nano-Additives Always Improve Electrified Lubrication? Insights from hBN-Containing Grease in Rolling Bearings Under Electrified Conditions" Technologies 14, no. 7: 389. https://doi.org/10.3390/technologies14070389
APA StyleBhaumik, S., Reddy, B. L. M., Paleu, V., & Chong, W. W. F. (2026). Do Nano-Additives Always Improve Electrified Lubrication? Insights from hBN-Containing Grease in Rolling Bearings Under Electrified Conditions. Technologies, 14(7), 389. https://doi.org/10.3390/technologies14070389

