Search Results (187)

The piston pin operates under severe mechanical and thermal conditions, making accurate lubrication prediction essential for engine durability. This study presents a comprehensive digital engineering framework for piston pin bearings, built upon a fully coupled thermo-elasto-hydrodynamic (TEHD) formulation. The framework integrates: (1) a Reynolds-equation hydrodynamic solver with temperature-/pressure-dependent viscosity and cavitation; (2) elastic deformation obtained from FEA (finite element analysis)-based compliance matrices; (3) a break-in module that iteratively adjusts surface profiles before steady-state simulation; (4) a three-body heat transfer model resolving heat conduction, convection, and solid–liquid interfacial heat exchange. Applied to a heavy-duty diesel engine, the framework reproduces experimentally observed behaviors, including bottom-edge rounding at the small end and the slow unidirectional drift of the floating pin. By integrating multi-physics modeling with design-level flexibility, this work aims to provide a robust digital twin for the piston-pin system, enabling virtual diagnostics, early-stage failure prediction, and data-driven design optimization for engine development. Full article

Oil additives are essential for improving anti-wear (AW) properties and durability of mechanical components. In this study, a novel ionic liquid based on phosphate ammonium salt (coded as IL-NPAS) was designed using organic synthesis methods. The high-level objective of this work is to enhance the wear resistance ability of oil-lubricated steels with low-cost additives in terms of materials and manufacturing methods. The IL-NPAS additive was incorporated at concentrations of 0.1 wt% and 0.5 wt% in 150 SN oil, which served as the base oil. Additionally, the commercial oil additive (coded as AW6110) was utilized as a reference to evaluate the effectiveness of the synthesized additive. The frictional behaviour was evaluated with an SRV tribometer at test temperatures of 25 °C and 100 °C. After that, SEM, 3D profilometry, XPS, and TOF-SIMS techniques were employed to show the wear modes and determine the chemical composition of the lubricating tribolayer. Noticeably, the formulated lubricant based on the 0.5 wt% IL-NPAS additive provided AW performance almost identical to the AW6110 additive. The results showed that the 0.5 wt% IL-NPAS additive reduced the coefficient of friction (COF) and improved AW properties by 34–36% and 80–90%, respectively, compared to the 150 SN base oil. Overall, this study holds significant promise for the development of low-cost lubricating oil additives. Full article

With the rapid advancements in industrial technology, the demand for high-performance lubrication has surpassed the capabilities of traditional solid or liquid lubricants. In this study, a novel MXene-based solvent-free lubricating nanofluid was developed through the surface functionalization of Ti₃C₂T_x MXene nanosheets. This innovative material combines the superior mechanical properties of solid Ti₃C₂T_x MXene nanosheets with the stable flow and rapid self-repairing capabilities of liquid lubricants. The successful synthesis of the MXene-based solvent-free nanofluid lubricant was confirmed through a series of characterization techniques, and it was demonstrated that this nanofluid maintained excellent flowability at room temperature. Subsequent tribological tests revealed that the friction coefficient and the wear performance of the MXene-based solvent-free nanofluid lubricant improved with increasing mass concentrations of Ti₃C₂T_x MXene nanosheets under consistently applied loads. These results indicate that the MXene-based solvent-free nanofluid lubricant significantly reduces friction and wear, showcasing its potential as a high-performance lubricant for industrial applications. Full article

Due to growing environmental challenges, many studies are focusing on vegetable-based lubricants. Industrial lubricants pose a significant risk to the environment and human health. The tribological performances of calophyllum calaba (galba) and avocado when used as a base oil and as a liquid additive were compared to those of moringa oil. The different lubricant formulations were investigated under an ambient atmosphere, using a reciprocating ball-on-plane tribometer in a boundary lubrication regime. Graphite particles were used as solid lubricant additives due to their excellent friction performances in these formulations. Dodecane was the mineral oil used as a reference and base oil in some lubricant formulations. It was found that the percentage used and the fatty acid molecule composition of vegetable oils have an important influence on the tribological performances of the different formulations. The presence of oleic acid molecules shows a positive effect but is not sufficient to explain the friction reduction obtained with moringa oil. The triglyceride shape of an oleic acid molecule is the key to an important friction reduction, despite the small amount (2 wt% as liquid additive) in lubricant formulations. Full article

Water is attractive as a base fluid due to its availability and environmental friendliness. To enhance its lubricity, environmentally friendly additives must be applied. This study combined protic ionic liquid and several nanoparticles to form hybrid additives for an oil-in-water lubricant. The performance of these additives was evaluated using wettability, tribo-testing, and worn-surface analysis. The tribo-test employed a ball-on-plate reciprocating tribometer that used bearing steel/bearing steel and WC/bearing steel friction pairs. The results were compared with those obtained using two commercial additives. It was found that the investigated additives are promising candidates for water-based lubricants, as they exhibit comparable wettability. Moreover, they outperform the reference samples in terms of lubricity. According to the results, the suggested lubrication mechanism includes enhanced wettability, composite tribo-film formation, surface polishing, and mending. Full article

Railway sites are characterized by the frequent occurrence of soil and groundwater pollution by oil. The primary reason for pollution is usually the handling of large volumes of fuels and lubricants and, to a lesser extent, other hazardous substances, which represent an increased likelihood of potential spills due to inattention and accidents. The second factor is spills due to inadequate (aged) process equipment. In the Slovak Republic, a network of locomotive depots, strategically located throughout the country, has been operated in the past. In 2008, a pilot project was implemented to survey groundwater quality at 45 sites, followed by monitoring of the quality status until 2014. The levels of petroleum hydrocarbons in groundwater were determined by spectrophotometric methods (NEC-IR and NEC-UV). The NEC-IR parameter documented very-high pollution at 14 sites, while the NEC-UV parameter documented the same very-high pollution degree at 23 sites. Statistical evaluation using Kruskal–Wallis test followed by Dunn’s post hoc test revealed a significant effect of the size of the site as well as activity status on the presence and intensity of pollution. The presence of light non-aqueous phase liquids (LNAPLs) was observed at almost half of the sites. Based on the evaluated data, railway sites represent a specific type of site with frequent occurrence of severe oil pollution, posing a significant environmental and health risk. Full article

During the actual service process, water-lubricated bearings on ships are often in complex operating environments such as low speed, heavy load and salt-sand water areas. To meet the requirements of high load-bearing capacity, long service life and the ability to discharge sand and dissipate heat during the service of bearings, research has been conducted on water-lubricated bearings made of polyetheretherketone (PEEK) with a semi-groove structure. Mathematical and physical models based on the averaged Reynolds equation have been established. By adopting the method of multi-physics field coupling, the lubrication characteristics of the bearings under the coupling influence of multiple factors in the salt-sand water environment (lubrication interface (the surface roughness of the bearing bush), different working conditions (water supply pressure, rotational speed, eccentricity)) are analyzed. Finally, a water-lubricated bearing test bench is set up to conduct bearing lubrication performance tests under multiple factors. The research shows that compared with liquid water, the salt-sand water environment exhibits better lubrication characteristics. The maximum water film pressure, the deformation amount of the bearing bush and the bearing capacity of the bearings increase with the increase of the rotational speed, water supply pressure and eccentricity, while the friction coefficient decreases. With the increase of the roughness of the bearing bush, these parameters decrease slightly and the friction coefficient increases. The presence of salt-sand particles can weaken the influence of roughness on the lubrication characteristics of the bearings. After considering the thermal effect, the mechanical load and thermal load act on the surface of the bearing bush together, resulting in an increase in the deformation amount of the bearing bush, a 0.11% drop in the water film pressure, and the highest temperature of the water film being concentrated at the outlet of the groove. The local semi-groove structure of PEEK can make the friction coefficient as low as 0.019. The comparison errors between the simulation and the experiment are within 10% (for water film pressure) and 2.6% (for friction coefficient), which verifies the reliability of the model. Full article

When exposed to high contact pressure and shear conditions, the sliding and/or rolling contact interfaces of moving mechanical systems can experience significant friction and wear losses, thereby impairing their efficiency, reliability, and environmental sustainability. Traditionally, these losses have been minimized using high-performance solid and liquid lubricants or surface engineering techniques like physical and chemical vapor deposition. However, increasingly harsh operating conditions of more advanced mechanical systems (including wind turbines, space mechanisms, electric vehicle drivetrains, etc.) render such traditional methods less effective or impractical over the long term. Looking ahead, an emerging and complementary solution could be tribocatalysis, a process that spontaneously triggers the formation of nanocarbon-based tribofilms in situ and on demand at lubricated interfaces, significantly reducing friction and wear even without the use of high-performance additives. These films often comprise a wide range of amorphous or disordered carbons, crystalline graphite, graphene, nano-onions, nanotubes, and other carbon nanostructures known for their outstanding friction and wear properties under the most demanding tribological conditions. This review highlights recent advances in understanding the underlying mechanisms involved in forming these carbon-based tribofilms, along with their potential applications in real-world mechanical systems. These examples underscore the scientific significance and industrial potential of tribocatalysis in further enhancing the efficiency, reliability, and environmental sustainability of future mechanical systems. Full article

Due to their excellent mechanical stability, chemical stability, and environmentally friendly properties, ceramic materials have received extensive attention for years. Meanwhile, ionic liquids (ILs) have been found to effectively enhance tribological properties when applied as lubricants, which has become a distinctive example of their wide exploration. Here, three novel proton-type ionic liquids containing different polar groups were designed and synthesized as pure lubricants for use on different ceramic friction couples (silicon nitride–silicon nitride, silicon nitride–silicon carbide, and silicon nitride–zirconium oxide contacts), and their lubrication effect was evident. The results indicate that the adsorption behavior and frictional characteristics of different polar groups on a ceramic friction interface differ, largely depending on tribochemical reactions and the formation of a double electric layer on the interface between the ILs and ceramic substrates, without obvious corrosion during sliding. The friction coefficient is reduced by more than 80%, and this excellent anti-friction effect demonstrates that the constructed ionic liquid–ceramic interface tribological system shows good application potential. Based on the analyses of SEM, EDS, and XPS, the tribochemical reaction on the sliding asperity and the film-forming effect were identified as the dominant lubrication mechanisms. Here, the high lubricity and anti-wear performance of ILs containing phosphorus elements on different ceramic contacts is emphasized, enriching the promising application of high-performance ILs for macroscale, high-efficiency lubrication and low wear, which is of significance for engineering and practical applications. Full article

In response to the IMO’s decarbonisation strategy, hydrogen—especially green hydrogen—becomes a promising alternative fuel in shipping. This article provides a comparative analysis of two hydrogen propulsion technologies suitable for a service vessel (SOV) operating in offshore wind farms: hydrogen fuel cells and hydrogen-powered internal combustion engines. This study focuses on the use of liquid hydrogen (LH₂) stored in cryogenic tanks and fuel cells as an alternative to the previously considered solution based on compressed hydrogen (CH₂) stored in high-pressure cylinders (700 bar) and internal combustion engines. The research aims to examine the feasibility of a fully hydrogen-powered SOV energy system. The analyses showed that the use of liquefied hydrogen in SOVs leads to the threefold reduction in tank volume (1001 m³ LH₂ vs. 3198 m³ CH₂) and the weight of the storage system (243 t vs. 647 t). Despite this, neither of the technologies provides the expected 2-week autonomy of SOVs. LH₂ storage allows for a maximum of 10 days of operation, which is still an improvement over the CH₂ gas variant (3 days). The main reason for this is that hydrogen tanks can only be located on the open deck. Although hydrogen fuel cells take up on average 13.7% more space than internal combustion engines, they are lower (by an average of 24.3%) and weigh less (by an average of 50.6%), and their modular design facilitates optimal arrangement in the engine room. In addition, the elimination of the exhaust system and lubrication simplifies the engine room layout, reducing its weight and space requirements. Most importantly, however, the use of fuel cells eliminates exhaust gas emissions into the atmosphere. Full article

Gallium-based liquid metal is corrosive to steel alloys, forming FeGa₃ surface films which can potentially be applied as a solid lubricant to enhance wear resistance and mitigate liquid metal-induced corrosion. However, the characteristics of these films remain insufficiently explored. In this study, Ga-In-Sn alloy was ultrasonically soldered onto annealed and decarburised substrates, followed by heating in a vacuum chamber to form a 30 μm thick FeGa₃ reaction layer. The film on the annealed samples with an alpha-ferrite microstructure exhibited high porosity and a surface roughness of 1.97 Ra. In contrast, the film on the decarburised samples with a ferritic microstructure showed minimal porosity and a lower surface roughness of 1.29 Ra. Nanoindentation tests revealed Young modulus values of 231 GPa and 242 GPa and hardness values of 11.4 GPa and 12.7 GPa for the annealed and decarburised samples, respectively. The high porosity in the annealed samples is attributed to the suppression of FeGa₃ formation in regions containing chromium carbides. Shear stress for fracture, measured by microcantilever tests at the interface between the substrate and the inner matrix of the surface film, showed lower fracture shear stress in the annealed sample, attributed to the presence of larger pores within its microstructure. Full article

Porous media gas bearings utilize gas as a lubricating medium to achieve non-contact support technology. Compared with traditional liquid-lubricated bearings or rolling bearings, they are more efficient and environmentally friendly. With the uniform gas film pressure of gas bearings, the rotating shaft can achieve mechanical motion with low friction, high rotational speed, and long service life. They have significant potential in improving energy efficiency and reducing carbon emissions, enabling oil-free lubrication. By eliminating the friction losses of traditional oil-lubricated bearings, porous media gas bearings can reduce the energy consumption of industrial rotating machinery by 15–25%, directly reducing fossil energy consumption, which is of great significance for promoting carbon neutrality goals. They have excellent prospects for future applications in the civil and military aviation fields. Based on the three-dimensional flow characteristics of the bearing’s fluid domain, this paper considers the influences of the transient flow field in the variable fluid domain of the gas film and the radial pressure gradient of the gas film, establishes a theoretical model and a three-dimensional simulation model for porous media gas bearings, and studies the static–dynamic pressure coupling mechanism of porous media gas bearings. Furthermore, through the trial production of bearings and performance tests, the static characteristics are verified, and the steady-state characteristics are studied through simulation, providing a basis for the application of gas bearings made from porous media materials in the civil and military aviation fields. Full article

The traction behavior in cryogenic solid-lubricated ball bearings (CSLBBs) used in liquid rocket engines (LREs) affects not only the dynamic response of the bearing but also the lubricity and wear characteristics of the solid lubrication coating. The traction coefficient between the ball and raceway depends on factors such as contact material, relative sliding velocity, and contact pressure. However, existing traction curve models for CSLBBs typically consider only one or two of these factors, limiting the accuracy and applicability of theoretical predictions. In this study, a novel traction model for CSLBBs is proposed, which incorporates the combined effects of contact material, relative sliding velocity, and contact pressure. Based on this model, a tribo-dynamic framework is developed to investigate the tribological and dynamic behavior of CSLBBs. The model is validated through both theoretical analysis and experimental data. Results show that the inclusion of solid lubricant effects significantly alters the relative sliding and frictional forces between the rolling elements and the raceway. These changes in turn influence the impact dynamics between the rolling elements and the cage, leading to notable variations in the bearing’s vibrational response. The findings may offer valuable insights for the wear resistance and vibration reduction design of CSLBBs. Full article

Vegetable oils are an important alternative to the massive use of fuels and lubricants from non-renewable energy sources. In this study, the physicochemical properties of coconut oil and waste cooking oil are investigated for biofuels and biolubricant applications. A transesterification of both oils was reached, and the transesterified oils were characterized by infrared analysis and gas chromatography. The lubricant performances of these oils have been evaluated using a ball-on-plane tribometer under an ambient atmosphere. Different formulations were developed using graphite particles as solid additive. Each initial and modified oil has been investigated as a base oil and as a liquid additive lubricant. The best friction reduction findings have been obtained for both initial oils as liquid additives, highlighting the key role of triglycerides in influencing tribological performances. Full article

The proposed tribometer design evaluates lubricants’ lubricating and wear protection properties at the interface of a loaded set of gears. However, this tribometer configuration and testing procedure described in standard ISO 14645-1 does not limit the tribological studies of gear test rigs. This study aimed to design and manufacture a mechanical transmission test rig capable of investigating the tribological condition of a lubricated enclosed gears transmission. The methodology consisted of (i) a definition of the test rig’s requirements; (ii) downsizing the main subassemblies present in the ISO 14635-1 test rig; (iii) designing innovative subassemblies; (iv) an instrumentation and data acquisition system, and (v) setup testing. The proposed system is suitable for evaluating small quantities of lubricants, allowing the analysis of special lubricants such as nanolubricants and ionic liquids in development for gearbox applications. Also, the dynamic loading avoids interruption in the test, providing results closer to working conditions. The experimental test evaluated the lubrication ability of two different base oils simultaneously under various loading conditions. Also, monitoring vibration signals helped identify the appearance of damage on the gear surface. Full article