Nanotechnology for Lubricants to Improve Performance and Reliability of Army Systems

Size: px

Start display at page:

Download "Nanotechnology for Lubricants to Improve Performance and Reliability of Army Systems"

Harvey Wade
5 years ago
Views:

1 Nanotechnology for Lubricants to Improve Performance and Reliability of Army Systems October 15, 2013 Ken Eberts, Mohit Jain and Ganesh Skandan NEI Corporation Somerset, NJ and Kristin B. Walker RAM & System Assessment Division, Redstone Arsenal 400 Apgar Drive Suite E Somerset, NJ V: (732) ; F: Program Sponsored by US Army SBIR Program W31P4Q-11-C-0194

2 About Us Founded in 1997 Today, conducting R&D, manufacturing and marketing diverse Advanced Materials products Two facilities in New Jersey (15,000 ft 2 space) Products sold under NANOMYTE trademark NEI building Shop floor Analytical Laboratory NEI building 400 E Apgar Drive 14C Worlds Fair Drive NEI Proprietary Information 2

materials) In-house capabilities to prove concept and demonstrate prototype in relevant environment Technology

3 Core Competency Nanotechnology expertise Bridge gap between basic and applied science by relating material properties to product performance Design and develop products (nanoparticles, nanocomposites and nanostructured materials) In-house capabilities to prove concept and demonstrate prototype in relevant environment Technology based, application driven, customer focused Nanotechnology Energy Environmental Sustainability NEI Proprietary Information 3

4 Nanomaterial Products Nanomyte Series for: Advanced Protective Coatings Energy Storage Materials Environmental Nanomaterials Nanoparticle Fluids NEI Proprietary Information 4

Application Need Lubricants used in the Army s ground and airborne vehicles Lubricants with more efficient heat transfer can lead to: - Reduced erosion of the gears -

5 Application Need Lubricants used in the Army s ground and airborne vehicles Lubricants with more efficient heat transfer can lead to: - Reduced erosion of the gears - Reduced downtime - Reduced maintenance costs - Extended operation Engineer the lubricant (oil/grease) to enhance heat transfer properties NEI Proprietary Information 5

Challenge Heat Transfer Correlation for Forced Convection in a Tube h k 2/3 C p 1/3 0.8 / 0.

= density of the fluid η = viscosity of the fluid Maximize Increase in Thermal Conductivity

6 Challenge Heat Transfer Correlation for Forced Convection in a Tube h k 2/3 C p 1/3 0.8 / h = heat transfer coefficient k = thermal conductivity of the fluid C p = heat capacity ρ = density of the fluid η = viscosity of the fluid Maximize Increase in Thermal Conductivity Minimize Increase in Viscosity Minimize Decrease in Heat Capacity Maintain or Improve Lubricity 6

7 Initial Work Base Fluid: Valvoline Synpower 75W90 (VV975) Gear Oil Additives Commercially available, Micron-Scale Additive: Micro-1 NEI-Synthesized, Nanostructured Additive: Nano-1 Commercially available, Micron-Scale Additive: Micro-2 NEI-Synthesized, Nanostructured Additive: Nano-2 7

After ~1 Week 133 132 131 130 129 Base Oil 128 0 100 200 300 400 Time @

8 Thermal Conductivity (mw/m-k) Results: Comparison of Dispersion Stability Over Time (without agitation) Nano-1 Micro-1 Dispersions After ~1 Week Base Oil C (hrs) Micro-1 Nano-1 Nanostructure allows for highly stable dispersions 8

Viscosity (cp) Results: Viscosity Measurements at 40 C 102 100 98 Micro-1 Nano-1 Base Oil 96

9 Viscosity (cp) Results: Viscosity Measurements at 40 C Micro-1 Nano-1 Base Oil Viscosity Reduction 90 More Newtonian Flow Shear Rate (s -1 ) 9

10 K (mw/m-k) Results: Comparison of Additive 1 and Additive 2 Thermal Conductivity of Dispersions in Oil at 40 C % % Base Oil Nano-1 Nano-2 10

140 Some reduction in VI for Nano-1 Significant increase in VI for Nano-2 130 120

11 Viscosity Index Results: Effect of Dispersed Solids on Viscosity Index (VI) ASTM D Kinematic Viscosity Calculated from Absolute Measurements Some reduction in VI for Nano-1 Significant increase in VI for Nano Base Oil Nano-1 Nano-2 Potentially Allows for Wider Operating Temperature Range 11

+ Commercial Nano Additive: Commercial (using

12 Scale-up and Independent Standardized Testing: Base Fluid: Valvoline Synpower VV975 Base Oil Base Fluid + Commercial Nano Additive: Commercial (using recommended amount) Base Fluid + NEI Nano Additive: Nano-2 12

13 Thermal Conductivity (mw/m-k) Results: Comparison of Oil Additives Thermal Conductivity of Oil Dispersions at 40 C Nano-2 Commercial Base Oil 13

14 Results: ASTM D2983 Low Temperature Viscosity, -40 C Viscosity (Pa s) Fail Pass Pass /Gear%20Lube%20White%20Paper.pdf 50 0 Base Oil Commercial Nano-2 14

Results: ASTM D2270 Viscosity Index Viscosity Index (ASTM D2270) 160 158 156 154 152 150

15 Results: ASTM D2270 Viscosity Index Viscosity Index (ASTM D2270) Base Oil Commercial Nano-2 15

16 Average Wear Scar Diameter (mm) Results: ASTM D Ball Wear Test Your Text 0.4 Scars form at contact points Base Oil Commercial Nano-2 16

17 Extreme Pressure Testing: ASTM D Ball EP Test ASTM D3733 Falex EP Test ASTM D Ball EP Test Your Text ASTM D3733 Falex EP Test Pin Example: Hypoid Gears /Gear%20Lube%20White%20Paper.pdf V-Block 17

Wear Index (ASTM D2783) Results: ASTM D2783 4 Ball EP Test Wear Index and

http://www.synthetic-oil-tech.com /Gear%20Lube%20White%20Paper.

18 Wear Index (ASTM D2783) Results: ASTM D Ball EP Test Wear Index and Weld Point lbs 500lbs Weld Point (lbs) 400lbs Weld /Gear%20Lube%20White%20Paper.pdf Your Text 30 High index indicates reduced friction Base Oil Commercial Nano-2 18

ASTM D3233B - Failure Load (lbf) Results: ASTM D3733 Falex EP Test Load to Failure 3500 3000 2500 2000 1500 Load to

19 ASTM D3233B - Failure Load (lbf) Results: ASTM D3733 Falex EP Test Load to Failure Load to failure (pin seizes) /Gear%20Lube%20White%20Paper.pdf Base Oil Commercial Nano-2 19

20 Product Development and Demonstration Further Optimization of High Conductivity Additives Surface Functionalize for Dispersion in Aviation Oils MIL-PRF-23699F Turbine Oil Aviation Gear Oil Performance Testing In-House USC Apache Drivetrain Facility 20

Thermal Conductivity (mw/m K) Optimization of Thermal Conductivity 155 150

21 Thermal Conductivity (mw/m K) Optimization of Thermal Conductivity % Base Oil 1% Micro-3 0.5% Nano-3 1% Nano-3 21

Thermal Conductivity (mw/m-k) Optimization of Stability 140 138 136 Nano-5

22 Thermal Conductivity (mw/m-k) Optimization of Stability Nano-5 Nano-6 Nano-7 Nano High Stability Time (hr) 22

23 Temperature ( C) Cooling Rate ( C/min) In-House Performance Testing Oil Thermocouple Shear Generator 8000RPM Cool Air ~23 C Control Oil Temp Nano-2 Oil Temp % Faster Cooling Time (min) 0 Control Nano-2 23

24 Simulated Use Conditions USC Apache Tail Rotor Drivetrain Facility Intermediate Gear Box (IGB) 24

25 Temperature ( F) Simulated Use Conditions Gearbox Operated Without Load Average Gearbox Temperature AGL Nano Time (sec) Cumulative Vibrational Energy 25

26 Temperature ( F) Simulated Use Conditions Gearbox Operated WITH Load ft-lb 730 ft-lb 980 ft-lb 1220 ft-lb AGL Average Gearbox Temperature Time (min) Nano-4 26

Amplitude (g) Amplitude (g) Simulated Use Conditions Gearbox Operated WITH Load Cumulative sum of enegies-after load step 3 300 Nano AGL 200 100 Cumulative

27 Amplitude (g) Amplitude (g) Simulated Use Conditions Gearbox Operated WITH Load Cumulative sum of enegies-after load step Nano AGL Cumulative Vibrational Energy Frequency (HZ) x 10 4 Nano AGL Cumulative sum of enegies-after load step Frequency (HZ) x

Future Development Incorporate nanocomposite particles in fully

nanocomposite particles In-house laboratory testing of lubricants

synthesis process In-House and external used lubricant analysis

28 Future Development Incorporate nanocomposite particles in fully formulated lubricants Synthesize nanocomposite particles Characterize nanocomposite particles In-house laboratory testing of lubricants Incorporate nanocomposite particles upstream during the lubricant synthesis process In-House and external used lubricant analysis Testing under simulated use conditions Long-term & field testing QUALIFICATION TESTING 28

Qualification Testing Viscosity Grade, per ASE and ISO Viscosity Index, ASTM D2270 Pour Point, ASTM D97 Flash Point, ASTM D92 Oxidation Resistance, ASTM

29 Qualification Testing Viscosity Grade, per ASE and ISO Viscosity Index, ASTM D2270 Pour Point, ASTM D97 Flash Point, ASTM D92 Oxidation Resistance, ASTM D943, D2272 Rust Protection, ASTM D665 Water Separability, ASTM D1401 Copper Corrosion, ASTM D130 Foam Test, ASTM D892 FZG Scuffing, ASTM D5182, DIN

30 Thank You