Tag: oil lubricants

How Long is Lubricant’s Shelf Life?

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When buying lubricants, you have to consider how long they will last. For high-volume users, this is not as much of an issue compared to smaller-volume users. High-volume users’ regularly consumer and reorder lubricants and typically have systems in place to monitor usage and spending. Small-volume users might be spread a drum or two of a lubricant through the course of a year. When consumption is spread out, you have to start to consider shelf-life into your purchasing decisions and operational processes.

Where can I find Shelf-Life Information?

Table made by George Wills and Dr. A.R. Landsdown

Information on a lubricant’s shelf life can be found on a technical or safety data sheet. If it is no t clearly defined, manufacturers and distributors can provide guidance on shelf life for its products. However, this information might be based on storage only or based on typical operations. George Wills and Dr. A.R. Landsdown provide a brief list of lubricants and their shelf-lives for products that have shorter shelf-lives.

Some technical data sheets (TDS) can show how long a lubricant can last in use before losing oxidation stability. This is measured in operating hours. Most oxidation tests will show a lubricant can last 5000+, 8000+, 10000+, etc. hours. However, like all scientific tests, this is done in a controlled environment (usually set by ISO or ASTM standards and specifications). We know that not every operating environment is like an ASTM or ISO test.

What Determines a Lubricant’s Shelf Life?

A lubricant’s shelf life depends on a variety of factors; some of which depend on the lubricant itself and some depend on usage. Greases have much shorter shelf life due to the presence of thickeners than oil-based lubricants. Highly-refined and synthetic oils have longer shelf lives due to better molecular stability. This is much more straight-forward and lubricant suppliers can inform you which lubricants last longer than others.

Using a lubricant is different for each operation. Some operations happen at low temperatures, others occur at high temperatures. The Arrhenius rate is a chemistry term that demonstrates how chemical reactions increase by changing temperature. For lubricants, as temperature increases by 10°C (18°F), the oxidation rate will double. The more oxidation that occurs, the faster a lubricant will break down and reduce the shelf life and effective use life.

Machinery Lubrication compiled a chart from its experts to show what can increase or decrease a lubricants shelf life.

Table Courtesy of Noria Corporation and Machinery Lubrication

 

How can you Reduce Oxidation?

Oxidation occurs when the lubricant comes into contact with air. Certain lubricants are more susceptible to faster oxidation and degradation due to the composition of the lubricant. However, these are known and can be accounted for, whereas human factors are a much greater influence on degradation and chemical stability.

Storage is key to maintain longer shelf-life and higher lubricant performance. Some things that can improve shelf-life include:

  • Storing lubricants in proper ambient temperatures. Cooler temperatures around 68°F are ideal.
  • Storing lubricants in dryer environments. Ambient humidity and moisture increase oxidation and lubricant breakdown.
  • Storing lubricants indoors. Outdoor storage can expose lubricants to more extreme and volatile conditions.
  • Storing lubricants in proper containers. Poor-quality steel containers can expose the oil to iron and fuel oxidation. Plastic or plastic-lined drums are ideal for storage.
  • Reduce agitation of the lubricant. The move the lubricant is agitated or moved, the more surface area of oil is exposed to air and can oxidize.
  • Evaluate usage and purchase lubricants accordingly. This smooths out spending, but also reduces the likelihood of using older products.
  • Practice First-In-First-Out (FIFO) when using lubricants. This prevents lubricants from sitting and aging.
  • Label lubricants, containers, and machines. Knowing when a lubricant was made or put into use allows individuals to be more mindful of when to change lubricants.

How do I Get Informed?

Unfortunately, there is no industry consensus on shelf-life. Following the tips above will extend and maintain shelf-life. Speaking with manufacturers, distributors, and engineers is the best option in getting product-specific shelf-life information. Manufacturers will know exactly what goes into their products and can provide shelf-life information and best practices for storage.

Twin Specialties can provide information about Best Practices for Lubricant Storage and Managing Metalworking Fluids. We work with manufacturers to provide transparency and information about lubricant shelf-life and usage. Contact Twin Specialties for information about lubricants, best practices, and shelf-life.

5 Factors for Drawing Fluid Selection

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In drawing processes, there two main types of lubrication. Firstly, there is fluid or hydrodynamic lubrication, which is the separation of metal surfaces with a continuous film of lubricant that prevents contact of those metal surfaces. Secondly, there is boundary lubrication, which is separating metal surfaces by a film only a few molecules thick.

The drawing process generates extreme pressures and the lubricant needs to perform to ensure proper separation of metal surfaces.

Factors for Drawing Fluid Selection

There are many factors that will affect lubricant selection. We will examine these factors and how they may affect lubricant selection and use. Considering these factors will ensure proper separation and excellent performance.

Type of Metal

Not all metals are alike. The first classification for metals is whether it is ferrous, non-ferrous, or an alloy. The hardness of metal will also be a key factor. Harder metals will require higher pressures, thus higher operating temperatures. A harder metal will need a lubricant that provides excellent cooling to prevent poor finishes or melting. Resistance to rust and corrosion varies metal to metal. Porous metals, such as cast iron, are porous and can rust quickly during annealing. Applications with those kinds of metals may require a lubricant that has rust/corrosion preventative additives.

Severity of Operations

The severity of the operation will be key to determining what kind of lubricant you need. Operations with extreme pressures may require lubricants with extreme-pressure and anti-wear additives to maintain proper lubrication. Operating speeds play a key role in determining the viscosity needed. Higher speeds will require lower viscosities so that the lubricant will adequately circulate. As temperatures rise, viscosity can degrade quickly. When the lubricant becomes too “thin” or “runny”, proper separation may be lost. Some lubricants will include viscosity index (VI) improvers to help maintain proper fluid thickness as temperatures rise.

Tooling

The tooling used in drawing may affect the lubricant selection. Some of the tools used in drawing include:

  1. Dies for cold drawing
  2. Rolls for forming strips and shapes
  3. Cutting tools
  4. Extrusion dies
  5. Heading dies
  6. Plugs
  7. Mandrels

The material of the tools also matters. In high temperatures, tool life may diminish and a lubricant that extends tool life improves performance and reduce costs. Tooling can be made of the following materials:

  1. Steel
  2. Carbide
  3. Diamond (synthetic or natural)

Subsequent Processes and Applications

Once a workpiece has completed the metal working process, most likely it still has to go through more manufacturing processes. Some of these include: annealing, cleaning, painting, and assembly into the final product. Cleaning the workpiece is import for final assembly as you want to avoid rust and corrosion. Drawing fluids that are emulsifiable are easier to clean and are preferred by some manufacturers. The cleaning process used also matters. Whether you use a dip tank, spray washer, or vapor degreaser, selecting a fluid that can wash away while also reducing rust and corrosion will be dependent on the cleaning process. Many fluid manufacturers, such as Twin Specialties, supply cleaners that are developed with their drawing fluids in mind.

Economic Considerations

With limited budgets, manufacturers must be pragmatic in selecting a fluid. Opting for a less expensive product may have hidden costs that are not realized at time of purchase. Lower quality fluids may reduce tool life and the fluid itself may need to be changed more frequently. These costs can add up and may not be realized until the job is completed. If your budget allows for it, opting for a synthetic fluid may prove to be a smart choice. Even though lubricants do not make up most of the budget, selecting the right lubricant can create tremendous cost savings on other parts of the income statement.

Takeaways

Each manufacturer has unique conditions and budgets; thus, no lubricant can be a one-size-fits-all product. Analyzing your metal workpieces, operations, tooling, cleaning and assembly processes, and budget will provide clarity. That clarity can aid lubricant selection and allow you to focus more on your manufacturing.

Working with manufacturers and distributors to determine the proper lubricant is the best strategy to maximize efficiency and boost the bottom line. Twin Specialties can analyze your processes and budget considerations to find the optimal lubricant.

A Guide to Base Oil Groups

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In any oil-based lubricant the base oil will compose 80-99% of the product you use. What are differences in the main ingredient of your lubricant? The American Petroleum Institute classifies base oils into 5 groups. These classifications are based on the chemical composition of the base oil and the treatment of the base oil.

If a base oil is classified as Group I-III, that base oil will be composed of crude oil that has been treated. The differences depend on the treatment processes applied to the oil.

Petroleum Base Oils

Group I

Group I base oils are the least refined base oil. Two main characteristics of Group I base oils are that they are composed of less than 90% saturates and/or greater than 0.03% sulfur. If either of these conditions are satisfied, then the base oil will be classified as Group I. The only process that is used is solvent refining, which allows Group I base oil products to be cheaper than their more refined equivalents. These are generally used for less-demanding applications and could be ideal for applications where lubricant consumption is high.

Group II

Group II base oils are more refined than Group I. In addition to solvent refining, these oils are also hydrocracked purify the oil. Unlike Group I base oils, these base oils must contain over 90% saturates and less than 0.03%. The greater percentage of saturates gives these lubricants better antioxidation properties than Group I base oils.

Failure to meet either of these requirements will result in a Group I classification. These products also have a viscosity index of 80-120. These oils have good performance in volatility, oxidation stability, wear prevention, and flash point. They only have fair performance in cold temperature environments. Given costs of treatment today, Group II lubricants are most commonly used today and many users have switched from Group I oils to Group II oils.

Unofficially, there is a Group II+ that are composed of high-end Group II base oils. These base oils must have a viscosity index of 110-120 to be considered Group II+.

Group III

Group II base oils must meet the same conditions (saturates and sulfur) as Group II, but also must have a viscosity index greater than 120. These base oils are severely hydrocracked, hydroisomerized, and hydrotreated to crate the best grade of petroleum base oil. These products offer superior stability and molecular uniformity, which makes them ideal for some semi-synthetic lubricants.

Some people consider Group III base oils to be synthetic. The API classifies them as mineral oil since they are derived from crude oil. They do mimic characteristics of synthetic oils including high viscosity indices. A lawsuit between Mobil and Castrol occurred due to Castrol marketing their Syntec lubricant as a synthetic even though it was composed of Group III base oils. In a 1999 ruling, the product was allowed to marketed as a synthetic.

Many people reject the decision and only consider Group IV and Group V base stocks as “synthetic.” Some Group III lubricants outperform Group IV lubricants if they contain excellent anti-wear, anti-oxidant, and other additives. Similar to Group II, Group III base oils have an unofficial Group III+, which consist of Group III oils that have a “Very High Viscosity Index (VHVI).” The VHVI minimum is anywhere between 130-140.

Synthetic Base Oils

Group IV

Group IV base oils are synthetic base oils that composed of polyalphaolefins (PAOs). These products have a viscosity index of 125-200. These base oils are not extracted from crude oil, but made from small uniform molecules. The uniformity and manufacturing of these oils allows for predictable properties that assure performance in tough conditions. These properties include extreme temperature stability, which makes these products ideal for cold and hot weather climates.

Lubricants composed of polyinternalolefins (PIOs) are considered to be in the unofficial Group VI. Similar to PAOs, PIOs use different chemicals in its synthesis process to obtain an even higher viscosity index. Their official API classification would be Group V. Certain food grade lubricants are composed of Group IV PAOs.

Group V

Group V base oils are any base oil that is not classified as a Group I-IV base oil. Common Group V base oils are polyalkylene glycols (PAGs) and various esters. One exception is white oil, which is a very pure lubricant commonly used in cosmetics and food processing. Also used in food grade lubricants, Group V base oils such as PAGs or esters can be used in certain biodegradable base stocks rather than vegetable or seed oils. It is important to note that most PAGs are only compatible with other PAGs.

Key Takeaways

When selecting a lubricant, it is important to understand what base oil is used. Given that the base oil is 80-99% of a lubricant, you should know what base oil you are using. Upgrading the Group III or Group IV could improve performance and reduce consumption. Twin Specialties offers a variety of industrial and specialty lubricants made from a variety of base stocks to meet your operating and budgetary requirements.

What are Aerospace Lubricants?

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On May 30, 2020, NASA and SpaceX partnered to send American astronauts from US soil to the International Space Station for the first time since 2011. As a new era spaceflight begins, government entities like NASA and private enterprises like SpaceX will work to innovate their rockets and push boundaries for human space flight. Lubricant manufacturers are tasked with the same challenges to create lubricants that will aid in the journey to reach our ambitious goals.

What are Aerospace Lubricants?

Lubricants in used in aerospace applications such as, space travel, commercial airlines, and defense, are like other lubricants, but face more stringent performance demands. In order to be classified as an aerospace lubricant, products must pass tests that are created by the Department of Defense (DoD) known as “MILSPECS.” To ensure safety and performance for aerospace applications, the MILSPECS create standardization to meet DoD objectives. These MILSPECS test different performance factors such as: corrosion protection, shear stability, compatibility, and water sensitivity.

What Differentiates Aerospace Lubricants?

In addition to meeting various MILSPECS, aerospace lubricants are engineered specifically for aircraft engines and fuel systems. The key difference between aerospace lubricants and non-aerospace lubricants is weight. In space operations, weight is crucial because more fuel is needed, which can become costly. It could also put a strain on how many other supplies could be included in the launch. As the safety of astronauts and functionality of equipment is vital, these lubricants cannot fail.

In space applications, lubricants face the most demanding tests. With temperatures in space at near Absolute-Zero and reentry temperatures reaching 5000 F, lubricants must perform in a wider-range of temperatures than their Earth-bound equivalents. Additionally, lubricants must be able to operate in a vacuum environment. This is on top of all of the crucial navigational and life-supporting machines that make space travel possibly. These machines cannot suffer any breakdowns or down time as they support life and other functions both in space and on Earth. Aerospace lubricants must have a long life to maintain these critical operations.

In defense operations, completing the objective is key and your lubricant must perform to ensure the objective is met. These lubricants have to: withstand extreme-temperature jet engines, cargo aircraft landing gears, precise navigational tools, and other wide-temperature components. By selecting lubricants that meet the right MILSPECS you can ensure proper performance and success in your aerospace operations.

Aerospace Lubricant Manufacturing

Aerospace lubricants in today’s markets can be in the form of liquids or greases. Most use synthetic base oils to achieve desired results and improve efficiency. Most of these lubricants are made of perfluoropolyether (PFPEs) or Multiply Alkylated Cyclopentane (MACs). Several large manufacturers produce these products that meet various MILSPECS. Twin Specialties has access to a wide variety aerospace and MILSPEC lubricants from Shell and Castrol. Contact us to learn more about our catalog.