Search Results (58)

The rapid growth of electric vehicles and electrified systems has increased the risk of bearing failures due to combined mechanical and electrical stresses. This study investigated the performance of hexagonal boron nitride nanoparticle-enhanced lithium grease under electrified conditions. Experiments based on a Taguchi L9 orthogonal array were conducted on deep groove ball bearings using a full-scale test rig at 1200 rpm with varying loads (100–300 N), currents (6–10 A), and hBN concentrations (0.1–1 wt.%). The tribo-electrical performance of nano-enhanced grease was compared with the base grease and commercial grease. It was observed that the base grease exhibited superior performance with a lower current flow, reduced vibration, and minimal surface degradation. In contrast, the hBN-enhanced grease exhibited inferior tribo-performance, with high vibrations and surface damage in electrified conditions. The surface analysis revealed features morphologically similar to white etching areas and micro-pitting. The FTIR results indicated grease degradation, while ICP-OES confirmed higher wear debris generation in the commercial and hBN-added greases. The present work indicates that additives like hBN nanoparticles do not necessarily improve performance under electrified conditions, making it important to consider the type of additives to be added during lubricant formulation. Thus, the findings emphasize the importance of lubricant formulation for controlling electrically induced bearing failures and provide insights for developing advanced greases for electric machinery applications. Full article

Fuel cell electric vehicles (FCEVs) require specific hydrogen purity, as even trace contaminants can degrade proton exchange membrane fuel cells (PEMFCs). While hydrogen quality is monitored along the supply chain according to international standards, potential contamination from in-vehicle materials, such as lubricants and greases, remains largely unexplored. Here, we present a staged testing framework consisting of (i) a rapid pre-screening for formulation stability and (ii) a full qualification pathway to assess lubricant-derived contamination under realistic refueling conditions. Candidate lubricants were exposed to hydrogen in a 700 bar Type IV vessel following an SAE J2601 refueling procedure. Contamination risks were evaluated by optical inspection, particulate matter, and gas analysis, monitoring contaminants specified in ISO 14687:2025 Grade D. The applicability of the framework was demonstrated in practical scenarios. In the pre-screening pathway, a silicone-based formulation fulfilled the 24 h acceptance criteria for formulation stability and was classified as potentially suitable for high-pressure hydrogen tank applications. In contrast, two other lubricants based on silicone and mineral oil exhibited visible changes associated with increased risk of particulate matter release, resulting in a classification of unsuitable. In the full qualification pathway, the fluorinated DuPont^TM MOLYKOTE^® HP-300 Grease was evaluated over 23 days and showed no release of harmful contaminants into the hydrogen gas, leading to the classification of suitable. Collectively, the presented protocols provide a structured basis for screening and qualifying lubricants for high-pressure hydrogen tanks in PEMFC applications, supporting future standardization in hydrogen technologies. Full article

The recent motivation for sustainable lubrication has driven the development and advances of bio-based and potentially environmentally favorable alternatives to petroleum-based greases. Yet, their industrial adoption is largely hindered by the thickener weak network or inconsistency leading to grease unacceptable degradation under applied loads and operating temperatures in rotating machinery. This study investigates a novel grease formulated from 80% palm oil and a 20% complex thickener system from carnauba wax (CW) and glycerol monostearate (GMS). The effect of thickener composition on grease performance was investigated by testing their X-ray diffraction (XRD) spectra, Fourier transform infrared (FTIR) spectra, penetration level, oil separation percentage, viscosity, thermal properties, and tribological behavior. GMS-rich blends achieved up to 70% lower friction than lithium grease. However, they showed high wear rates and excessive oil separation ranging from 0.07% at room temperature for the 20% GMS blend to above 9% at 40 °C for softer formulations. The blend of 15% CW + 5% GMS showed only 0.113% and 3.145% oil bleed at room temperature and at 40 °C, respectively, with suitable consistency (NLGI 3) and acceptable dynamic viscosity rates. Regarding thermal behavior, CW-based samples revealed an enhanced melting point compared to GMS. For validation, investigations were conducted on rolling element bearings on a customized test setup operating at 1400 rpm under selected radial loads. The results demonstrate that CW/GMS bio-thickeners achieved lower vibration levels compared to the GMS thickener, approaching the performance of lithium grease. Full article

Pin–bushing bearings in heavy-duty construction machinery operating in severe industrial environments are susceptible to accelerated wear, grease degradation, and lubrication failure, yet application-specific guidance for lubricant selection and re-greasing intervals under such conditions remains limited. This study evaluates the combined effects of bushing material (hardened steel, cast bronze, and Cu–Sn alloy), grease type (three commercially used greases with viscosities of 120, 460, and 150 mm²/s at 40 °C), and lubrication interval (8, 12, and 24 h) on grease-condition indicators in a field-operating wheel loader used in slag handling, where surrounding slag temperatures may reach 700–800 °C. A Taguchi L9 orthogonal array was used to define nine experimental configurations, each applied for approximately one week under real operating conditions. Grease samples were characterised using the SKF grease analysis kit based on NLGI consistency grade, base oil release rate, and contamination particle count. All greases showed an increase in NLGI grade from 2 to 3–4 during service, indicating thickening and a possible risk of lubrication channel blockage. Oil release rates decreased by up to 60% in some configurations, indicating reduced base oil mobility during service. When the three grease-condition indicators were evaluated together by Grey Relational Analysis, the combination of steel bushing, type B grease (ISO VG 460, lithium complex with MoS₂), and a 12 h lubrication interval showed the most balanced overall response. These findings provide field-based guidance for grease selection and maintenance scheduling in pin–bushing systems operating under demanding service conditions. Full article

This study investigates the influence of the additive illite on the thermal, tribological, and energy efficiency characteristics of calcium grease (CG) at different concentrations (0.05 wt.%, 0.1 wt.%, 0.2 wt.%, 0.4 wt.%, 0.6 wt.%, and 0.8 wt.%). Thermo-gravimetric analysis under inert and oxidative atmospheres revealed that illite enhances thermal stability by increasing inorganic residue under N₂, but promotes oxidative degradation under O₂, limiting practical thermal use to around 400 °C. Grease with 0.1 wt.% illite (CGI2) performed well in tribological tests by reducing the coefficient of friction and wear scar diameter by 53% and 57%, respectively, compared to the base grease. Fleischer’s energy-based wear model showed that all grease samples operated within the mixed friction regime, and CGI2 exhibited a 93% higher apparent frictional energy density and a substantially lower wear intensity that was 47% lower than the base grease, indicating improved energy dissipation and wear resistance. All samples had the same weld load (1568 N), but CGI2 had a 21% higher load–wear index than the base grease in the extreme-pressure test, indicating better load-carrying capacity. In the energy consumption test, a 6% reduction in current consumption was observed in CGI2 in comparison with the base grease. Overall, illite at an optimal concentration significantly enhances lubrication performance, wear protection, and energy efficiency. Full article

Continuous advancements in application technology aimed at higher efficiency and power density place ever-increasing demands on mechanical components and construction elements—and, consequently, on the lubricating greases employed. This is particularly true for rolling bearings, where greases are exposed to high mechanical loads and wide temperature ranges. A current example can be found in the bearings of hybrid vehicle powertrains, which are subjected to extreme thermal and mechanical stress due to engine downsizing, high rotational speeds, and radiant heat from the combustion engine. A collaborative project between the Competence Center for Tribology (KTM) at Mannheim University of Applied Sciences and the OWI Science for Fuels gGmbH (OWI), affiliated with RWTH Aachen University, demonstrated that the loss of lubricating performance—which ultimately leads to bearing failure—is directly linked to changes in the thickener structure. Various degradation processes reduce yield stress and viscosity, thereby eliminating the typical grease characteristics. Mechanical, thermal, oxidative, and catalytic processes all play decisive roles. This paper presents analytical methods that enable these individual influencing factors to be investigated and evaluated independently. These approaches can significantly reduce the need for time-consuming and costly laboratory tests in grease development and qualification. Full article

Throughout the lifetime, road markings (RMs) accumulate dirt, oils, and greases, which reduce visibility, shorten service life, and compromise road safety. If RMs could degrade these pollutants, their service life would increase. When exposed to UV light and humidity, semiconductors, such as titanium dioxide (TiO₂), can interact with contaminants and promote their chemical degradation. Semiconductors are commonly used on different types of substrates to achieve self-cleaning ability. In this study, 0.25–3 wt% TiO₂ was incorporated into a commercial RM paint for this purpose. After functionalization, the RM paint samples were contaminated with Methylene Blue and Rhodamine B. After pollution, the specimens were irradiated with a light source that simulates sunlight. To assess the self-cleaning capacity of the paints, visual analysis, color variation and discoloration by using CIELAB color coordinates, diffuse reflectance, and digital image processing techniques were applied. In both techniques, the samples with 2% and 3% of TiO₂ showed a greater capacity to degrade pollutants. Further, the chemical and morphological characteristics of the reference paint and the samples that showed the best self-cleaning results were analyzed by using Fourier Transform Infrared Spectroscopy (FTIR), Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray Spectroscopy (EDS), and X-ray Diffraction (XRD). They identified the polymer, filler, and pigment in the commercial paint and confirmed the TiO₂ increase after functionalization. This study demonstrated the innovative potential of incorporating semiconductors to achieve a new capability (self-cleaning) for RM paints. This breakthrough not only has the potential to extend the RM service life, but also to improve road safety through greater visibility. Full article

Environmental contamination critically affects the durability and performance of lubricants in machine components. Over long operating periods, particles and water ingress through degraded seals accelerate grease degradation and deteriorate tribological behavior. This study evaluates the effects of SiO₂ particle concentration and water contamination, alone and in combination, on the performance of calcium-based grease in bearing steel contacts. Friction coefficients, grease temperatures, wear, pitting, and vibration signals were analyzed. The results show that an increase in particle concentration raised both friction and temperature, leading to more severe wear and pitting. The addition of 0.6 wt% water reduced fluctuations in friction and temperature, but when combined with high particle concentrations, it significantly worsened wear and pitting. The vibration-based energy ratio correlated strongly with pitting evolution, highlighting its potential as a sensitive parameter for monitoring surface fatigue. These findings provide insights into lubricant degradation under contaminated conditions and offer guidance for improving the reliability of lubricated systems. Full article

Fats, oils, and grease (FOG) deposits are hardened, sticky, insoluble solids that accumulate in sewage systems globally. These deposits contribute to pipe blockages and sanitary sewer overflows, releasing pathogens and pollutants into the environment, posing significant environmental and public health risks. Current removal methods are labor-intensive and costly, emphasizing the need for alternatives. While biological strategies offer a viable alternative, the microbial breakdown of FOG is poorly understood. In this study, we evaluated the potential of individual microbial strains and synthetic microbial communities to biodegrade wastewater-derived FOG deposit samples. These biological agents were applied to a range of FOG samples, and biodegradation was assessed through visual observations such as color change or gas bubbles, particle size, cell counts, pH, weight loss, and changes in fatty acid profile. Results demonstrate that microbial augmentation can enhance FOG degradation, offering an alternative or complementary approach for reducing maintenance burdens and preventing sewer blockages. Full article

Polyurea grease (PU) is widely used in the lubrication of heavy machinery, but it can still suffer from structural or performance degradation under extreme conditions such as high temperatures and heavy loads. This study successfully synthesized a hybrid polyurea grease (LiTFSI-PU) by incorporating lithium bis(trifluoromethanesulfonyl)imide (LiTFSI) into polyurea matrix. LiTFSI coordinates with the carbonyl groups (C=O) in the thickener molecules to form weakly Lewis acidic complex, thereby reinforcing the soap fiber network structure. As a result, LiTFSI-PU exhibits increased apparent viscosity under shear. The tribological properties of LiTFSI-PU were evaluated under both ambient and elevated temperature conditions. At a load of 200 N and 150 °C, the average coefficient of friction for the 3 wt% LiTFSI-PU formulation was 0.094, which is 32.3% lower than that of the baseline polyurea grease (PU), while the wear volume was reduced by 77.5%. XPS and FIB-STEM/EDS analyses confirmed that LiTFSI-PU forms a multicomponent protective film in situ during friction, which simultaneously shields the substrate and provides lubrication. The additive strategy proposed in this work offers novel insights for the development of high-performance lubricants suitable for extreme thermomechanical conditions. Full article

Encapsulation of lubricating agents has many advantages, as it helps to protect them from external factors, oxidation and degradation, can support their controlled and prolonged release, and also preserves the environment from accidental contamination with these substances. In our experiments various types of thermo-responsive, paraffin wax capsules capable of safely transporting liquid and semi-solid lubricants were designed, fabricated and tested. Lubricating oils were primarily encapsulated inside hemispherical wax shells closed with special caps, but also in wax spherocylinders and two-compartment structures. Greases were protected with wax coatings with the thickness ranging from 0.187 to 0.774 mm. The payload release from our core–shell capsules occurred not only due to the exerted mechanical force but also in a controlled manner upon prolonged contact with a heated surface. The wax shells of the capsules lying on the plate, whose temperature was increased at a rate of 0.025°C/s, began to melt gradually, starting from ≈55.5 °C. This temperature-triggered lubricant liberation can be useful when, for example, a machine element becomes excessively hot due to friction. The wax itself also has lubricating properties, so the crushed or melted coating cannot be treated as waste, but only as an additional factor supporting lubrication. The practical applications of our wax capsules were demonstrated with five examples. Full article

Thermodynamic free energy is used to elucidate the significance of energy dissipation-induced temperature rise on the performance, reliability, and durability of all systems, biological, chemical and physical. Transformation (a measure of reliability) and degradation (a measure of durability) are distinguished. The temperature rise mechanism is characterized by the microstructurothermal (MST) energy/entropy. A framework to quantify the contributions of the MST entropy to system transformation and degradation is introduced and demonstrated using diverse multi-physics systems: cardiovascular strain in humans, charge capacity of batteries, tribological wear of journal bearings, and shear strength of lubricating greases. Various levels of temperature-induced degradation are observed in the systems. Thermal degradation rate increases with process and energy dissipation rates. The benefits of active cooling on systems and materials are shown. This article is recommended to engineers, scientists, designers, medical doctors, and other system analysts for use in dissipation/degradation characterization and minimization. Full article

Deep groove ball bearings are important mechanical elements in the automotive and process industries, particularly in electric motors. One of the primary reasons for their failure is lubricant degradation due to stray shaft current. Thus, the present work exhibited the failure of bearings under simulated lubricated conditions similar to those of real time bearings failing in presence of stray electric current. The test was conducted using a full bearing test rig with an applied radial load, 496 N, an alternating current, 10 A, and a rotation of 2000 rpm for 24 h. The bearings (6206 series) were greased using two commercially available ester-polyalphaolefin oil-based greases with viscosity 46–54 cSt (Grease 1) and 32–35 cSt (Grease 2, also contained aromatic oil). The optical microscopic images of the bearing raceways after the tribo test indicated the superior performance of Grease 1 compared to Grease 2, with lesser formation of white etching areas, micro-pitting, spot welds, and fluting on the surfaces of the bearings. Additionally, 80% less vibrations were recorded during the test with Grease 1, indicating a stable lubricating film of Grease 1 during the test as compared to Grease 2. Furthermore, a higher extent of Grease 2 degradation during the tribo test was also confirmed using Fourier transform infrared spectroscopy. Statistical analysis (t-test) indicated the significant variation of the vibrations produced during the test with electrified conditions. The present work indicated that the composition of the greases plays a significant role in controlling the bearing failures. Full article

Aluminum Conductors Steel-Reinforced (ACSR) conductors are typically used in overhead transmission lines. Corrosion is an important degradation mechanisms that might affect the lifetime of this essential electricity network component. Considering the complexity of conductors, it is difficult to predict the damage of these conductors in corrosive environments. The objective of this paper is to evaluate the effect of grease and conductor geometry on the mechanical properties of aluminum strand composing the envelope of ASCR conductors. Thus, ACSR wires and strands have been evaluated in corrosion by the mean of accelerated corrosion tests. Tensile, fatigue and torsion test results are presented to examine the effect of corrosion on aluminum strands. The influence of corrosion on mechanical characteristics is established by a decrease in ductility, maximum elongation and tensile strength for the longest exposition (336 days). This significant reduction in the internal layer of ungreased wires confirms the importance of the galvanic corrosion mechanism of aluminum wires. This evolution concerns only aluminum wires of non-greased conductors, confirming the crucial role of grease as protection against corrosion. Full article

Proper surface lubrication with optimal grease thickness is essential for extending steel wire rope service life. To achieve automated lubrication quality control and address challenges like variable lighting and motion blur that degrade recognition accuracy in practical settings, this paper proposes an improved lightweight GEMR-MobileViT. The model is designed to identify the grease thickness on steel wire rope surfaces while mitigating the high parameters and computational complexity of existing models. In this model, part of the standard convolution is replaced by GhostConv, a novel efficient multi-scale attention (EMA) module is introduced into the local expression part of the MobileViT block, and the structure of residual connections within the MobileViT block is designed. A transfer learning method is then employed. A custom dataset of steel wire rope lubrication images was constructed for model training. The experimental results demonstrated that GEMR-MobileViT achieved a recognition accuracy of 96.63% across five grease thickness categories, with 4.19 M params and 1.31 GFLOPs computational complexity. Compared to the pre-improvement version, recognition accuracy improved by 4.4%, while its parameters and computational complexity were reduced by 15.2% and 10.3%, respectively. When compared with current mainstream classification models such as ConvNeXtV2, EfficientNetV2, EdgeNeXt, NextViT, and MobileNetV4, our GEMR-MobileViT achieved superior recognition accuracy and demonstrated significant advantages in its model parameters, striking a good balance between recognition precision and model size. The proposed model facilitates deployment in steel wire rope lubrication working sites, enabling the real-time monitoring of surface grease thickness, thereby offering a novel approach for automating steel wire rope maintenance. Full article