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Applied Materials Division Argonne Nation Laboratory 9700 S. Cass Avenue Argonne, IL 60439
CCEFP Summit at the University of Wisconsin-Madison October 22-24, 2019
INTRODUCTION
System design and architecture – High power density – size and weight
reduction
Component design and materials – Reliability and durability of energy efficient
system
Working fluid properties and behavior – Minimal viscous and boundary friction
losses – Minimal leakage
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BACKGROUND
Volumetric and mechanical efficiencies of pump dependent on both fluid and material properties
Fluid properties to increase efficiency – Viscosity – as low as possible
• VI as high as possible • Thermal and shear stable with time
– Bulk modulus – as high as possible – Traction – as low as possible – Boundary friction as low as possible
Coating Properties for efficiency, reliability and durability – Boundary friction – as low as possible – Wear – as low as possible – Scuffing load/pressure – as high as
possible
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fluid and materials • Biodegradable - fluid • Good corrosion resistant • Cost effective • Renewable – for fluid • Others … depending on
application
DEVELOPMENT OF COMPOSITE BASE-FLUID
Lubricants and hydraulic fluids consist mainly (85-95%) of base fluid – Performance of fully formulated fluid is strongly dependent on properties of basefluid – Optimization of pertinent basefluid properties essential for development of energy efficient
lubricants and hydraulic fluids – Additives are used primarily to further enhance appropriate properties in fully formulated fluids
Using the approach of materials properties enhancement through mixture, new composite base fluids are being developed.
Borrowing from material science
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Advanced mineral oils • Performance similar to synthetic basestock • Stability over a medium temperature range • Polar molecules, more reactive. • Cost is an advantage • Group III, group III+
PAOs • Most widely used synthetic basestock • Stability over a medium temperature range • Non-polar molecules, less reactive. • Cost is an advantage
Synthetic Esters • Polyol esters, di-esters, • Stability over a wide temperature range • Low volatility and high flash point • Inherent lubricity and wear protection (polar)
Bio-Esters • From Palm, soy and sunflower oils • Renewable source • Bio-derived • Biodegradable PAG • Oil soluble polygleticycols, • Very high viscosity index • Stability over a very wide temperature range • Can be biodegradable
Binary and tertiary composite fluids from different fluids can provide a cost effective basestock for advanced new generation hydraulic and lubricant oil formulation
RHEOLOGICAL PROPERTIES- Viscosity and VI
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• Achieved viscosity and VI comparable to current advanced benchmark fluids
• Variation of VI with composition – indicative of opportunity for further optimization
• Cold crank viscosity of composite fluid superior to mineral-oil based commercial fluid and comparable to advanced synthetic fluid
Fluid Visc-40°C Visc-100°C VI Mono-32 32.2 5.48 105 Multi-32 33.43 6.51 152 Synthetic 32.50 6.78 173.7
PAO10 69.68 10.53 138 25-BioE1 63.34 8.39 158
50-BioE1 30.40 6.14 155 75-BioE1 18.76 4.63 175 100-BioE1 12.69 3.42 153
Kinematic viscosity and VI
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0
1000
2000
3000
4000
5000
Composite fluid (no additives) with lower wear under reciprocating sliding contact compared to benchmark commercial fully formulated lubricants
Minimal formation of surface tribofilm with composite fluid (no additives)
Steel on cast iron contact under reciprocating sliding
SCUFFING PERFORMANCE
7 FF-M
Brass Ball Volume Wear
Large wear seen in brass balls with fully formulated commercial fluids due to occurrence of scuffing
Minimal wear with no friction increase seen in unformulated composite basefluids
ADVANCED COATINGS DEVELOPMENT
EXTRACTING DLC AND OTHER CARBON NANOSTRUCTURES FROM LUBRICATING OILS, IN-SITU?
Oil Molecules
MeN
MeNMeN
The Case of MoNx-Cu
Nanocomposite of Hard and Soft Catalyst Phases Me: V, Mo, Nb, W, . . .
Cu Ni
1.3 GPa
10 hour test
COMPARISON OF WEAR
MoN-Cu coating in PAO 10 52100 in PAO 10 52100 in 5W30
WEAR ON FLAT SIDE 14
Nc-Coated in PAO 10 Steel in PAO 10 Steel in 5w30 oil
0.0 0.3 0.6 0.9 -0.4
-0.2
0.0
-0.4
-0.2
0.0
0.2
-0.4
-0.2
0.0
0.2
0.5
1.0
1.5
2.0
D CHx
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500*88*10 mm Copper target
Ar/N2 mixture atmosphere
Working Temperature 250ºC
V Target HPPMS Power (Power Density)
4000 W (9 W/cm2)
120 W (0.27 W/cm2)
20 30 40 50 60 70 80 90 0
200
400
600
800
1000
1200
VN (200)
In te
ns ity
(JCPDS 65-0437)
O 9.88 at.% N 35.14 at.% V 41.11 at% Cu 13.87 at.%
XRD shows VN-Cu coating is single phase with FCC lattice structure
XPS shows the coating contains almost 14% Cu
COATING MICROSTRUCTURE AND COMPOSITION MON-CU
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2,000
4,000
0
10,000
20,000
30,000
40,000
)
Binding Energy (eV) 404 402 400 398 396 394 392 390 388
600
700
800
900
1,000
1,100
1,200
900
1,000
1,100
1,200
1,300
1,400
1,500
1,600
a b
c d
XRD shows coating consists of 2 phases – MoN and Mo2N plus some Cu
XPS shows coating composition of about 5% Cu
MECHANICAL PROPERTIES
Rockwell C – Adhesion Test
2,000
4,000
6,000
8,000
10,000
12,000
14,000
MoN-Cu Coating
HF1 Rockwell C – Adhesion Test
Both coatings have similar hardness of about 20GPa, and excellent adhesion to the substrate
FRICTION AND WEAR EVALUATION Boundary lubrication with fully formulated hydraulic fluids
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Test Parameters: • 10RPM • 5µl Lubricant (Tier 2&3)
• A monograde mineral oil (Rando HD-32) • A multigrade mineral oil (Rando HDZ-32)
and • A synthetic high fluid.
• 6hr duration • 10 N Load
BASELINE MATERIALS AND COATINGS IN BASE/FORMULATED OILS (6 HOUR-TEST)
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0 50 100 150 200 250 300 350 400 0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.16
0.18
0.20
0.22
0.24
Uncoated/Baseline DLC-Coated/Baseline
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• MoN-Cu/MoN-Cu
Wear
Substantial boundary friction reduction in a variety of commercial hydraulic fluids Minimal wear on the coatings
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0 50 100 150 200 250 300 350 400 0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.16
0.18
0.20
0.22
0.24
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Catalytically active nano-composite (CAN) coatings provide lower CoF and wear behavior in sliding contacts compared to uncoated or DLC coatings
– Both coating reduced boundary friction and wear in different commercial hydraulic fluids
– Both coating’s performance superior than state of art DLC coatings
Integration of both composite fluid an coatings technology may result even further friction and wear improvements
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www.anl.gov
introduction
Background
Scuffing Performance
Extracting DLC and Other Carbon Nanostructures From Lubricating Oils, In-Situ?
Slide Number 11
Comparison of Wear
Deposition Conditions for VN-Cu and MoN-Cu
Coating Microstructure and Composition
Mechanical Properties
MoN-Cu-coated steel in base and formulated
VN-Cu-coated steel in base and formulated
Latest/Optimized ANL Coating in base/formulated fluids
Summary & Conclusions