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Introduction to Specialist Lubricants Mako-Lube Lubricants Limited
Presentation by:Gavin Armitage
Mako-Lube Lubrication Ltd Managing Director
Background to Mako-Lube Lubricants
Mako-Lube Lubricants is an independent specialty lubricant manufacturer based in Manchester, United Kingdom.
Mako-Lube Lubricants is the sister Company of Brit-Lube who were formed in year 2000. Mako-Lube formed in 2011 as the export division. “ An exciting new brand for Distribution only !”
Current Distributors in UK, Ireland, China, Thailand, Canada, South Africa, Brazil, Norway, Sweden, Ecuador……..
Mako-Lube Lubricants have purpose built modern production facilities in the UK.All product are manufactured & packaged in the UK.
Background to Mako-Lube Lubricants Group
Mako-Lube Lubricants offers a world class range of products.
Mako-Lube Lubricants has affiliate companies & distributors.
Mako-Lube Lubricants are represented worldwide.
Mako-Lube Lubricants specialise in high performance lubricants and lubrication including a complete range of synthetic oils, high performance, high and low temperature greases, fluid and dry film coatings.
Product Range
Unrivalled Product Portfolio Food-Tek Indu-Tek Ultra-Tek Xtreme-Tek
Manufactured to a quality, not a cost
High performance
Application Specific
Bespoke to customers specification
Access on www.mako-lube.com - Members Area !
Mako-Lube Lubricants service many sectors….
Automotive
Aerospace
Conveyors & Chains
Corrugating Machines
Food Industry
Electrical Industry
Textile Machinery
Faucets, Valves & Fittings
Moulding
Casting Metalworking
Oxygen
BASIC LUBRICANT TRAINING
The Refining Process
KECAtmos tower
Vacuumtower
desulphuri-ser units
WSR
Kerosine
GasoilKerosine
Diesel
Base Oils
Naphtha
Sulphurplant Sulphur
Lube Oil Unit
pda Bitumen
Heavy Oils
Light Oils
Crude Oil Distillation
CNG
LPG
gasoline
heavier fuels:
bigger molecules
aromatics
CH3
alkenes
(olefins)
CH3 CH3
cycloalkanes
(naphthenes)
CH3
alkanes
(paraffins)
CH4CH3 CH3
CH3
CH3
CH3 CH3
CH3CH3
CH3
CH3 CH3
CH3
CH3 CH3 CH3
CH3
CH3
CH3
Distillation is fluid separation on boiling point
INTRODUCTION
Lubrication has been practiced for centuries. Early lubrication involved the use of water or animal fat to improve free running and reduce wear. Chariot wheels were lubricated with rendered animal fat. Modern lubricants are more sophisticated, but similar principles are involved.
Reduction of friction & wear.
BASIC LUBRICATION THEORY
At a microscopic scale, even apparently smooth surfaces are actually quite rough. Friction and wear result when these rough surfaces move across each other. *
BASIC LUBRICATION THEORY
Lubricants act between the opposing surfaces, reducing friction and wear. Maintenance of the lubricant film is paramount; loss of lubrication leads to huge increases in friction; hence wear, seizure and component failure.
FRICTION REGIMES
HYDRODYNAMIC ‘Aquaplaning’
BOUNDARY ‘Last ditch’
MIXED EHD (lowest friction)
SLA - Solid Lubricating Additives Explained
PTFE
Oil
Graphite
MoS2
*
SOLID LUBRICANTSSOLIDS WITH SPECIAL PROPERTIES
LOW INTERNAL FRICTION, SOFTNESS
EXTREME TEMPERATURE RESISTANCE, CAN BE USED ALONE OR AS ADDITIVES…
GRAPHITE, MOLYBDENUM DISULPHIDE (MOLY or MoS2), PTFE (TEFLON), MINERALS, SOFT METALS…
MOLY & GRAPHITE: The crystals are arranged in layers which slide easily over one another, GRAPHITE…up to 600°C, MoS2…up to 450°C DECK OF CARDS
Other solids include Talc, Mica, Boron Nitride, Zinc sulphide and Tungsten disulphide, similar layer structure.
PTFE/ TEFLON: Very low friction solid “Described as the Slipperiest Substance in the World!” Struggles under very high load.
PTFE SAMLPLES, GRAPHITE & MOLY
COEFFICIENT OF FRICTIONThis is a measure of the ‘slipperiness or lubricity of a system. For a simple bearing, it varies with rotational
speed, loading and viscosity of any lubricant.
An Inclined plane
BASIC TYPES OF LUBRICANTS
OILS
GREASES
SOLID LUBRICANTS
DRY FILM COATINGS
OTHER FLUIDS
OILS
LUBRICATING OILS are made from a blend of base oils and additives
BASE OILS may be of many different types
ADDITIVES are included to improve the performance of the base oil
TYPES OF BASE OIL
VEGETABLE (OR ANIMAL)
MINERAL OIL
SYNTHETIC HYDROCARBON
SYNTHETIC NON-HYDROCARBON
*
TYPES OF ADDITIVES
• VI IMPROVERS
• CORROSION INHIBITORS
• ANTI-WEAR AGENTS
• ANTI-OXIDANTS
• EP ADDITIVES
• DETERGENTS
• ANTI-FOAMS
VEGETABLE OILS
CHEAP
BIODEGRADABLE
NATURALLY VARIABLE QUALITY
LIMITED RANGE
UNSUITABLE FOR EXTREME TEMPERATURES
CHEMICALLY UNSTABLE
MINERAL OILS
CHEAP
MODERATE CHEMICAL STABILITY
WIDE RANGE OF GRADES
NATURALLY VARIABLE QUALITY
UNSUITABLE FOR EXTREME TEMPERATURES
NON-BIODEGRADABLE
SYNTHETIC HYDROCARBONS
PURE MOLECULES
HIGHER CHEMICAL STABILITY
RELATIVELY EXPENSIVE
MAY BE BIODEGRADABLE
TYPES OF SYNTHETIC HYDROCARBONS
POLY ALPHA OLEFINS (PAOs) Synthetic mineral oil without
the impurities. Higher temperature resistance, less lacquer, same additives.
POLY ALKYLENE GLYCOLS (PAGs) Can be oil soluble, water
soluble or neither. Very low lacquer, higher temperature resistance. PAG additives are generally less effective.
ESTERS DIESTERS. Better temperature
resistance than PAGs. More expensive.
TRIESTERS. Better temperature resistance than diesters. Still more expensive
POLYOL ESTERS. Best temperature resistance of the esters. Unlike the previous synthetic oils these are biodegradable. Yet more expensive.
NON-HYDROCARBON OILS
SILICONES
Wide temperature range, high price
FLUOROSILICONES
Wider temperature range, higher price
FLUOROCARBONS, PFPEs
Widest temperature range, highest price
*
BENEFITS OF NON-HYDROCARBONS
COMPATIBLE WITH SEALS
VERY HIGH CHEMICAL STABILITY
CHEMICAL INCOMPATIBILITY
EXPENSIVE TO EXTREMELY EXPENSIVE
VISCOSITY & VIViscosity is an important parameter. Film thickness increases with viscosity, but so does friction. At low speeds, a viscous oil is best, at high speeds a light mobile fluid is preferred, as long as it is viscous enough to keep the surfaces separate!
The standard temperatures of measurement are 40°C & 100°C. The unit of measurement is the ‘centistoke’ cSt.
The viscosity also determines the ‘grade’ of oil. For example, ISO VG 220 oils are around 220 cSt @ 40°C
The property of viscosity varying with temperature is measured by the Viscosity Index, or VI – different oils have different Viscosity indexes. The VI is calculated from the difference in the viscosity at 40 & 100°C,Less change in Viscosity with temperature = a higher VI
Oil Viscosities - Explained
High Speed, Low Load
High Load, Low Speed
*
Conclusion :- Oils
All oils are not the same
Finished products are basically a blend
Finished products of the same nature i.e. Esters, Mineral Oils etc. may perform differently as performance is due to specific “Additive Packages” used.
Rule of Thumb – Higher the Viscosity – Lower the speed, higher the load
Some Mako-Lube products have SLA’s Solid Lubricating Additives added for improved performance & friction reduction. i.e. MOS2 & Teflon/PTFE
GREASES
Greases are thickened oils.
Formulated greases therefore contain:-
BASE OIL
ADDITIVES
THICKENER
GREASE =
100 %
More Common
Less Common
BASE OIL +
(70 – 95%)
SYNTHETIC OILS
Dialkylbenzène
Polyalphaolefins
Esters
Polyglycols
Silicones
Perfluoropolyethers
Polyphenylethers
THICKENER +
(3 – 20%)SIMPLE SOAPS
Lithium
Calcium
Sodium
Aluminium
Barium (rare)
INORGANIC
Bentone
Silica
Polyurea
PTFE & other solids
ADDITIVES
Corrosion inhibitors
Anti wear
Extreme pressure
Antioxidant
Polymers
Anti copper
Solid Lubricants
Colourings
Friction Modifiers
Metal powders
ADDITIVES
(0 – 10%)
COMPLEX SOAPS
Calcium
Lithium
Aluminium
Barium (rare)
MINERAL OILS
Paraffinic
Naphthenic
COMPOSITION OF GREASES
What is a Grease?A grease is a mixture of a base lubricating fluid (usually a mineral or a synthetic oil) and a thickener (usually a soap) dispersed in the oil.
Designed to provide extended lubrication intervals by gradually allowing the base fluid to provide lubrication between working surfaces.
More specialised greases contain additional additives to enhance high temperature and anti-wear performance and to provide corrosion protection.
31
Grease Composition
SOAPS & COMPLEXES
These are the most common greases. They contain no solid matter and are suitable for general purpose applications
SOAPS are simpler cheaper formulations. Limited by melting point
Most common Lithium i.e. Lithium EP 2 Grease
COMPLEXES have greater resistance to high temperatures, water & steam “Act Like a Sponge” to draw the oil film back into the grease. Sponge Demo
Lithium Complex, Calcium Complex, Aluminum Complex, Barium Complex etc.
Properties depend upon the chemical attributes of the thickener
Note: Lithium Grease & Lithium Complex have completely different performance characteristics but “Sound” the same
What goes into a specialised grease?
• Base Oil• Thickener• EP / Anti-wear Additives• Solid Lubricants• Oxidation Inhibitors• Corrosion Inhibitors
33
Grease Composition
Base Oil
Provides hydrodynamic lubrication
Types of Base Oil
Mineral Oil (-30ºC to 150ºC)
Synthetic Oil (-70ºC to 300ºC)
Vegetable Oil (-10ºC to 130ºC)
34
Grease Composition
ThickenerActs as a sponge and releases small quantities of oil when worked
Types of ThickenerSoaps: Lithium, Calcium, Aluminum, Sodium
Powders: Silica, Clay (Bentone), PTFE – Teflon
WHEN CHANGING FROM ONE TYPE OF GREASE TO ANOTHER, ALWAYS CHECK COMPATIBILITY!
35
Grease Composition
EP AdditivesChlorine, Sulphur, Phosphorus. EP Additives react with the metal surface when friction generates momentary high temperatures
Solid LubricantsMolybdenum Disulphide (MoS2)
GraphitePTFEWhite Solids
36
Grease Composition
*
Anti-oxidantsProtects base oil by delaying the onset of oxidation caused by high temperatures. This is one of the key ingredients in extending grease life.
Anti-corrosion agentsProvide protection of metal surfaces operating in wet, corrosive conditions.
37
Grease Composition
38
Cone Penetration – NLGI Grading – National Lubricating grease Institute
Cone is set so that it just touches surface of grease. Temp 25ºC
Cone is released and allowed to sink into the grease for 5 secs.
Depth of Penetration measured in 0.1mm
NLGI 6
NLGI 5
NLGI 4
NLGI 3
NLGI 2
NLGI 1
NLGI 0
NLGI 00
NLGI 000
HOW IS GREASE THICKNESS MEASURED?
Synfood EP 1Synfood EP 2 Synfood EP 000
NLGI No. (National Lubricating Grease Institute)
No. Penetration Consistency Food Comparison
6 85 – 115 Block grease Cheddar Cheese
5 130 - 160 Extremely stiff grease Smooth Pate
4 175 - 205 Very stiff grease Frozen Yogurt
3 220 - 250 Stiff grease Lard
2 265 - 295 Standard grease (85% of grease market) Peanut Butter
1 310 - 340 Soft grease (for centralised lube systems) Tomato Paste
0 355 - 385 Very soft grease ( “ “ “ ) Mustard
00 400 - 430 Semi fluid grease Apple Sauce
000 445 - 475 Fluid ‘slumping’ grease Cooking oil
40
Cone released onto a flattened surface of a worked sample of grease, left for 5 seconds, depth of penetration measured in 0.1mm
Consistency - NLGI
*
41
Penetration - Grease Worker
To establish “Worked Penetration”, the grease is subjected to 60 strokes in a grease worker, where the grease is forced backwards and forwards through a perforated disc.
42
Shell 4 Ball
No lubricant satisfies all working conditions
68% of bearings fail prematurely
• Half of this due to incorrect lubrication
Causes:
Initial over-lubrication
Over-lubrication at frequent lube intervals
Infrequent lubrication
Mixing greases of different types
Incorrect lubricant
43
Selection of the correct lubricant is key
So often grease is applied until it is seen to extrude through the bearing housing.
44
Over-lubrication
Recommended lubrication 60%
Over-Lubrication
Why the wrong lubricant?
Misjudgment of operating conditions:• Temperature• Water• Speed• Dust• Load• Chemicals• Bearing Type• Method of application
Wrong recommendation by supplier
45
Selection of the correct lubricant is key
Recommending an equivalent or alternative:
How often does the lubricant supplier ask about the application and working conditions?
How sure is the lubricant supplier that the product put forward is the best one for the job? Never match a current grease always Specifiy what “YOU” determine is best for the application !
46
Selection of the correct lubricant is key
Non – Grease CompoundsANTI SEIZES-SOFT
METALSSoft metals can be used as anti-seize materials
(e.g. Anti-Seize 1100 ) at extreme temperatures. (i.e. over 600°C) Sacrificial layer of soft metal allows release from seizure.
Nickel & Lead are toxic
Copper is an environmental hazard
Aluminium is not as effective at high temperatures.
They are NOT greases and should not be used for bearing lubrication
Used for bolts, threaded fittings, slides, sleeves etc. Protection against seizure of threads caused by high temperature or corrosive conditions, dismantled parts can be re-used *
Other ProductsDRY FILM COATINGS
Dry film lubricants are used in many areas as a thin film of a low friction ‘paint’ or coating to provide lubrication and corrosion protection:
1. SOLVENT / WATER DISPERSIONS – solid particles of lubricant held in a carrier solution or dispersion – Mako-Cote Range
2. BONDED COATINGS –They contain solvent, resin (to bond to the surface) & lubricant. The dried film is resin + lubricant:- a compromise. Dry Moly & PTFE Sprays *
Conclusion :-
Oils & Greases are Blends!
Performance is defined by base fluid properties & additives packages etc
SLA’s Reduce friction & improve performance
Oils & Greases come in many different forms, Fluid, Semi-Fluid, Compounds, Greases, Water-Based, Aerosols, Trigger Sprays, Solvent Based, Resins etc
Thank you for your time!Any questions?
Mako-Lube LtdUnits 2&3 Mayfield Industrial Estate
Liverpool Road Irlam
Manchester M44 6GD
+44(0)161 777 [email protected]