Lubricants are substances that reduce friction and wear between two surfaces in contact with each other, under a heavy load. The science of lubrication involves considering several important factors, such as an understanding of the nature and properties of the various materials in sliding or rolling contact with each other, as well as the friction and wear mechanisms to which they are subjected. We often use different types of lubricants for different machines and equipment. Therefore, the formulation technologies of each lubricant are different from each other. There are several types of lubricants including oils, greases, penetrating lubricants, and dry lubricants. They are designed to reduce friction and wear under a variety of load, speed, and temperature conditions. They have been widely used for sealing, protection, and any other purpose to extend the life of the entire system by efficiently applying it to a particular surface. It cools and cleans the system, preventing sludge deposition and contamination. The purpose of a lubricant is essentially to allow metal parts to function smoothly. Lubricant additives are used to modify the properties of the oil to make it a better metal surface.
For a lubricant to function properly between interacting solid surfaces, it must possess certain minimum properties, as well as avoid certain behaviors that are harmful. Its success arises from the ability to achieve and sustain a small, yet adequate, layer of lubricant between the moving parts. The interacting surfaces may consist of metals, ceramics, polymers, or any combination. Therefore, the lubricant should be compatible with all sorts of materials and combinations. Also, they are employed in a wide variety of machinery from large combustion engines to small gears and bearings. In terms of compatibility and performance, one type of lubricant might not be the best for every application. In order to develop a suitable lubricant that meets specific requirements, lubricant manufacturers must have a thorough understanding of the machinery, its operating conditions, and its lubrication situation.
The science of lubrication formulation involves the combination of various substances to create a product that meets the specific standards of engines and machinery. This process involves a lot of engineering principles, and a deep understanding of chemistry, and material science. These mechanisms are often different in different lubricants. Furthermore, the lubricant companies must comply with and meet the industrial standards and requirements in addition to the specific formulations and chemistry. This blog discusses the science of lubricant formulation and the fundamental elements that give lubricants their unique and useful properties.
Key Ingredients In Lubricant Formulation
1. Base Oil
Base oils are the foundation of any lubricant. Today’s base oils fall into one of three main lubricant categories: conventional/mineral, synthetic, and refined. The base oils typically make up 70% – 90% of the final product.
The mineral base oils are mainly formulated from crude oils which have a weight similar to that of the final product. The lubricant manufacturers enhance its quality as a lubricant by adding antioxidants, dispersants, and cleaning agents. The lubricants made from mineral base oils are now considered traditional lubricants. Nevertheless, today’s vehicles still operate well using these products.
The synthetic base oils are formulated from uniform molecules such as petrochemicals and esters to ensure superior performance in extreme conditions. The refined base oils have fewer impurities compared to other base oils. These base oils can provide more stability and better performance henceforth can be used in a broad range of applications.
Each of these base oils has its own specifications, and base oil manufacturers blend them to produce the final lubricant. The specifications that consumers most frequently consider are the pour point, flash point, appearance, and viscosity measured at different temperatures.
2. Additives
Additives are the magic components that improve the quality of base oils formulating them to meet the specific requirements of lubricants. There are different types of additives including Extreme pressure (EP) agents, friction modifiers, antioxidants, foam inhibitors, anti-wear agents, detergents and dispersants, viscosity index modifiers, and so on.
- Viscosity Index Improvers – These are large molecules that, when cooled, can uncoil and leave spaces between segments that resemble cylinders. They create a loose grid at lower temperatures, which results in reduced fluidity and a rise in lubricant viscosity. The viscosity index rises with these qualities. Viscosity index improvers react to high temperatures by typically reducing their structure. By reducing their apparent size, the lubricant’s apparent viscosity is lowered and less resistance is created. This allows unrestricted internal flow up to service temperatures, preserving fluidity.
- Antioxidants – Over time, the lubricant might subjected to oxidation. However, the antioxidants in the lubricant will prevent the lubricant from oxidising, reducing the risk of sludge formation. With this property, the lubricant will function efficiently for a prolonged period.
- Anti-Corrosion Inhibitors – Many of the engines and machinery are exposed to water and moisture, increasing the chances of corrosion in the metal parts. Therefore, using a lubricant with superior-quality anti-corrosion agents will help the engine function optimally. The anti-corrosion inhibitors are special types of additives that create a protective layer between the metal parts to prevent them from rust and corrosion. It protects lubricating oil against degradation under severe heat, and a variety of air and water-borne corrosive elements found in the lubrication site.
- Foam Inhibitors – They are generally silicone or synthetic wax, which generates a minimally wettable surface. They reduce foam formation, preventing inadequate lubrication and operational issues.
- Detergents & Dispersants – They are typically applied as mixtures and are designed for the control of deposits in many and various engines. They prevent the deposition of contaminants and sludge formation, keeping the engine clean. Also, detergents help to neutralize the acid content in the engine parts and dispersants suspend the solid particles within the lubricant.
- Friction Modifiers – These chemicals manage the frictional properties of the lubricant. are in many instances oily compositions based on chemical interaction and are utilized or added for winter performance. Some of the best friction modifiers are graphite and molybdenum disulfide.
- Anti-Wear Additives – These substances will help the lubricant create a protective barrier between the metal parts, minimizing friction, and thereby reducing the risks of premature wear and tear. The presence of these agents in a lubricating oil also helps in preventing the scoring of machinery parts.
- Thickeners – Lithium, calcium-based compounds, polyurea, etc. are the most common thickeners used in the formulation of lubricants such as greases. In these types of lubricants, they need a semi-solid consistency. That’s why the thickeners hold a crucial role in the lubricant manufacturing process. They also prevent any kind of lubricant leakage and ensure that the lubricant stays in place under high pressure conditions.
- Performance Enhancers – For some specific applications, lubricant needs performance enhancers like demulsifiers and extreme pressure (EP)additives. EP additives have the ability to protect metal surfaces from scuffing or scoring under extreme conditions. They form a protective barrier to prevent metal-to-metal contact during heavy loads and high pressure conditions. And, the demulsifiers can help the oil in removing the water contamination from them, ensuring a more effective lubrication.
The Role Of Lubricant Manufacturers
Lubricant manufacturers have the key functions of developing or producing new lubricant formulations and providing suitable base oils, additives, and formulated lubricants to oil users. Besides providing formulated lubricants, they also help the end users in covering their maintenance and other various market requests as well as technical services. Their primary function is the lubricant formulation depending on the various industrial applications, from the most basic internal combustion engine to hydraulic systems in aerospace equipment. Lubricant manufacturers develop new lubricants with advanced technology to improve the properties of previously formulated lubricants, comply with new regulations and meet new technical needs. They provide technical information on the formulated lubricants, including biodegradability, environmental risks, and health and safety information, and are also responsible for waste management.
For a perfectly formulated lubricant, ensuring quality and product integrity is an important stage. It is at this stage that the advanced scientific and industrial facilities of a lubricant supplier are required. Companies vary considerably in the extent of their Research and Development organization, but even the smallest lubricant marketer is likely to have some laboratory facilities for quality control and testing. However, even though a lubricant manufacturer doesn’t have a laboratory for these quality checks, there are independent service firms whose laboratories are designed to perform the necessary tests. Anyhow, quality control and testing are an integral part of the formulation process of lubricants.
Another thing the lubricant manufacturers are most invested in is the research and development of lubricants. They are involved in continuous research so that the finished product continues to meet the needs of the many diverse applications. They need to balance the compatibility between base oils and additives to meet the industry standards and requirements of various applications including automobile, marine, industrial, construction, agricultural, and so on.
Also, there are several stringent industry standards and regulations a lubricant manufacturer must follow while formulating a lubricant. Formulating a lubricant requires the lubricant manufacturer to understand the needs and product offerings of various vehicle manufacturers and then relay this knowledge to the additive and base oil manufacturers. It involves several steps and processes. They also conduct various tests to ensure that the newly formulated lubricant meets these criteria.
Lubricant formulation is a complex process that involves several processes from the careful selection of base oils and additives to quality checks and testing. A lubricant is simply a mixture of substances that is designed to improve the performance and lifespan of an engine. There are different types of lubricants, varying from engine oils to hydraulic fluids. Also, the ingredients and formulation technology of each lubricant are different from one another. Following and investing in these technologies and methods are imperative for lubricant manufacturers to be successful in this field. The perfect composition of base oil and additives, innovative formulation technologies, meeting the industry standards, and ensuring superior quality of the fluid will embark on a great path for lubricant suppliers in this industry.
