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 08873 V: (732) 868-3141; F: -3143 www.neicorporation.com Program Sponsored by US Army SBIR Program W31P4Q-11-C-0194
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
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
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 - 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 / 0.467 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
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
Thermal Conductivity (mw/m-k) Results: Comparison of Dispersion Stability Over Time (without agitation) 136 135 134 Nano-1 Micro-1 Dispersions After ~1 Week 133 132 131 130 129 Base Oil 128 0 100 200 300 400 Time @ 40 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 94 92 Viscosity Reduction 90 More Newtonian Flow 88 86 0 10 20 30 40 50 Shear Rate (s -1 ) 9
K (mw/m-k) Results: Comparison of Additive 1 and Additive 2 Thermal Conductivity of Dispersions in Oil at 40 C 150 145 + 11% 140 135 + 3% 130 125 120 Base Oil Nano-1 Nano-2 10
Viscosity Index Results: Effect of Dispersed Solids on Viscosity Index (VI) ASTM D2270 - Kinematic Viscosity Calculated from Absolute Measurements 180 170 160 150 140 Some reduction in VI for Nano-1 Significant increase in VI for Nano-2 130 120 Base Oil Nano-1 Nano-2 Potentially Allows for Wider Operating Temperature Range 11
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
Thermal Conductivity (mw/m-k) Results: Comparison of Oil Additives Thermal Conductivity of Oil Dispersions at 40 C 145 140 135 130 125 120 Nano-2 Commercial Base Oil 13
Results: ASTM D2983 Low Temperature Viscosity, -40 C Viscosity (Pa s) 250 200 Fail 150 100 Pass Pass http://www.synthetic-oil-tech.com /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 http://www.flitalia.it/en/fl/manuale/en/trasm_0103.htm 148 146 Base Oil Commercial Nano-2 15
Average Wear Scar Diameter (mm) Results: ASTM D4172 4 Ball Wear Test 1.2 1 0.8 0.6 Your Text 0.4 Scars form at contact points 0.2 0 Base Oil Commercial Nano-2 16
Extreme Pressure Testing: ASTM D2783 4 Ball EP Test ASTM D3733 Falex EP Test ASTM D2783 4 Ball EP Test Your Text ASTM D3733 Falex EP Test Pin Example: Hypoid Gears http://www.synthetic-oil-tech.com /Gear%20Lube%20White%20Paper.pdf V-Block 17
Wear Index (ASTM D2783) Results: ASTM D2783 4 Ball EP Test Wear Index and Weld Point 90 80 70 60 50 40 500lbs 500lbs Weld Point (lbs) 400lbs Weld http://www.synthetic-oil-tech.com /Gear%20Lube%20White%20Paper.pdf Your Text 30 High index indicates reduced friction 20 10 0 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 failure (pin seizes) http://www.synthetic-oil-tech.com /Gear%20Lube%20White%20Paper.pdf 1000 500 0 Base Oil Commercial Nano-2 19
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 17% 145 140 135 130 125 120 115 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 Nano-6 Nano-7 Nano-8 134 High Stability 132 130 128 0 20 40 60 80 100 120 Time (hr) 22
Temperature ( C) Cooling Rate ( C/min) In-House Performance Testing Oil Thermocouple Shear Generator 8000RPM Cool Air ~23 C 85 80 Control Oil Temp Nano-2 Oil Temp 10 8 6 60% Faster Cooling 75 4 2 70 45 46 47 48 Time (min) 0 Control Nano-2 23
Simulated Use Conditions USC Apache Tail Rotor Drivetrain Facility Intermediate Gear Box (IGB) 24
Temperature ( F) Simulated Use Conditions Gearbox Operated Without Load 250 200 Average Gearbox Temperature 150 100 50 AGL Nano-4 0 0 500 1000 1500 2000 Time (sec) Cumulative Vibrational Energy 25
Temperature ( F) Simulated Use Conditions Gearbox Operated WITH Load 300 250 370 ft-lb 730 ft-lb 980 ft-lb 1220 ft-lb AGL Average Gearbox Temperature 200 150 100 50 0 0 100 200 300 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 Vibrational Energy 300 0 0 0.5 1 1.5 2 2.5 Frequency (HZ) x 10 4 Nano AGL Cumulative sum of enegies-after load step 4 200 100 0 0 0.5 1 1.5 2 2.5 Frequency (HZ) x 10 4 27
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 D943, D2272 Rust Protection, ASTM D665 Water Separability, ASTM D1401 Copper Corrosion, ASTM D130 Foam Test, ASTM D892 FZG Scuffing, ASTM D5182, DIN 51534 29
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