Lubricants Development to Meet Fuel Economy & Reduction on CO 2 Emission on Light & Heavy Duty Diesel Vehicles

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1 Lubricants Development to Meet Fuel Economy & Reduction on CO 2 Emission on Light & Heavy Duty Diesel Vehicles Dr. Mathew Abraham Mahindra & Mahindra Ltd., India

2 Drivers for Vehicle Design Regulatory Sustainability Air Pollution Customer Emission norms FE Norms Tightened norms Fuel Economy Conservation of Fossil fuel Emission in Cities Critical Vehicle share on Emission rising GHG Emission Control Cost Neutral Offering Reliable Vehicles Exponential Advancement on Engine & Vehicle Technology

3 Emission Norms: EU & India Decision by Govt. BS 6

4 Emission & FE Norms in India FY BS IV Norms Decision by Govt. BS V Norms BS VI Norms BS VI Norms CAFC Fuel # Consumption (Gasoline Equiv.) Phase l/100KM, 1037 kg Kerb Weight Phase L/100km, 1145 kg Kerb Star Rating Phase-1 Phase -2 # Fuel consumption calculated from CO 2

5 Current Scenario In India Diesel Vehicles perceived to be cause for Emission in City SC impose ban on Diesel Cars above 2000cc Engines at National Capital Region-Delhi Govt. skip BS V to BS VI by 2020 Fuel Quality relaxed compared to other mature countries OEMs face immense challenge for Technology acceleration & validation to meet these targets

6 Engine Oil Spec for UV/SUV Long Drain Oil SAE15W 40 Base Oil Gr I & II API CH4, CI4 ACEA A3/B3 FE & Long Drain Oils SAE xx W 30, xxw 20 Base oil Gr III/PAO API CI, CI+ ACEA A5/B5 Additional Top treat Oil for ATD & FE SAE xxw 30, xxw 20 Base Oil: Gr III/ PAO API: CJ4 ACEA: C3/C5, E6/E9 Additional Top treat

7 Engine Oil Spec for HD Vehicles Long Drain Oil SAE15W 40 / 20W 40 Base Oil Gr I & II API CH4, CI4 FE & Long Drain Oils SAE xx W 30 HTHS : >3.5 Base oil Gr III/PAO API CI4, CI4+& OEM specs ACEA E4 / E6 Oil for ATD & FE SAE xxw 30 HTHS <3.5 Base Oil: Gr III/ PAO API: CJ4/CK4/PC-11B ACEA: E7/E9

8 Current Scenario Why oil development important? ØLow friction lubricants are the most cost effective easy implementable method to benefit Fuel Economy & CO 2 Emission Reduction

9 Engine Oil Design Drivers Fuel Economy Ensure durability Drain intervals Vary with segment 10 to 20K for Cars & SUVs 60 to 100K for HD Vehicles Customer affordability Specification customized for segment Possibly standardized Complex situation considering backward integrity

10 FE Engine Oils Characteristics Friction performance depends on: Base oils Oil viscosity Shear properties: HTHS Additive technology Friction modifiers

11 Methods of Evaluation Engine level BSFC Vehicle level FE measurement (NEDC cycle) On road FE measurement RWUP verification

12 Effect of Base oils & Viscosity 1.72 Fuel Economy, % improvement 0.00 Ref XX-40 XX-30-1 XX-30-2 XX-30-3 All candidates are XX-30 1 st is Group III, 2 nd and 3 rd are Group II 1 st & 2 nd are same KV & HTHS 3 rd is same KV but slightly higher HTHS

13 Effect of Rheology on FE improvement FUEL ECONOMY, % IMPROVEMENT KV optimized KV & HTHS optimized Ref xx-20 xx-20 Ref xx-20 xx-20 Ref is XX-30 KV optimization provide FE improvement but, limited KV & HTHS together provide significant improvement

14 How Friction Modifier Impact? Fuel Economy, % improvement 0.97 Improvement with xx-30 two chemistry No improvement with xx-30 Ref Ref 1 Ref 1 + FM 1 Ref 1 + FM 1 Ref 2 Ref 2 + FM 1 Ref 3 Ref 3 + FM 1 All ref are xx-30 have similar HTHS & comparable o C FM content equal in all the cases Behavior not Consistent Interacts differently with Additive Chemistry

15 Friction modifiers Vs Formulation Fuel Economy, % improvement FM1 shows 0.5% to 1% improvement in new formulations FM2 & FM3 do not show improvement FM chemistry & interaction with formulation is critical

16 Transmission Oil Study q Transmission fluids are normally focused for shift performance and durability q Possess good scope of FE improvement support q Optimization of transmission fluid for synchro performance, durability and FE benefit is challenge Photo courtesy: Lubrizol

17 Transmission oil & Efficiency Oil A Ref - 80W90 Gr I Oil B 75W90 Gr III Oil C 75W85 Gr III Oil D 75W90 - PAO Joint work of M&M and Lubrizol Optimization of transmission oil with respect to rheology & chemistry has effect on Friction reduction & efficiency improvement Synthetic base oil not necessarily required to give optimum performance

18 Durability Performance of oil Good vs Bad All in tact High deposits, gear pitting and burning mark

19 Case Study FE on SUV UVs with Common Rail Diesel engine Ø Meeting BS-III and BS-IV emission norms Trial in controlled condition & on road condition Ø Urban and extra urban driving cycle followed Fleet of 40 vehicles utilized for trial Ø 10 controlled condition & 30 regular usage profile Oils on focus Engine & Driveline fluids Ø Ø Proprietary formulations Formulation optimized to give FE meeting Durability & Drain period targets

20 FE Tests SUV FE Improvement with Engine oil Reference Oil : SAE 15W 40, API CI4, A3/B3 Candidate: SAE XX-30 % Improement EEC EUDC EEC+EUDC FE Improvement with transmission & Axle Lubricants 6 % Improement Min Max Average Reference Oils : SAE XX-90

21 FE Tests on SUV FE Improvement, % Fuel Economy Improvement in vehicle - SUV FE performance of Optimum oil formulation meeting system durability performance & target drain period 0.0 Base FE Cycle 1 FE Cycle 2 Average of 2 cycles

22 Case Study FE on HD Vehicle Engine Tests Engine dyno BSFC mapping 13 mode emission cycle Back to back test with reference & candidates Vehicle on road tests Test procedure followed : SAE 1526 Fuel consumption measurement : Gravimetric Method Test length 160 km (100 miles) Conducted in break-in vehicle

23 HD Vehicle FE Tests BSFC measurement FE on road tests FE Improvement, % Ref Pack 1 Pack 2 Pack 3 FE Improvement, % FE Pack 2 FE Pack 3

24 Conclusions FE & CO 2 Reduction through low friction lubricants important & easy to adopt Optimization of fluid properties for an application is real challenge Low viscous & HTHS formulations give FE but need to ensure durability Engine oils with similar KV & HTHS profile differ in FE improvement q Selection of additives and base oil critical Frictional modifiers helps to improve FE q All type of FMs do not provide improvement q To be compatible with formulation else counter-productive Usage of PAO Base oils to be selectively done if needed; else customer affordability will be difficult

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